Kia_Sephia_Rio_Spectra_Optima_1998-2006

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Drain and recycle the engine oil.
  10.  
  11. Remove or disconnect the following:

    Positive Crankcase Ventilation (PCV) and crankcase ventilation hoses
     
    Accelerator and, if equipped, the cruise control cables
     
    Air intake hose from the throttle body
     
    Brake vacuum hose and the purge control vacuum hose
     
    Ventilation hose and fresh air duct
     
    Upper radiator hose
     
    Fuel hose from the fuel injector rail
     
    Heater hoses
     
    Idle Air Control (IAC) and Throttle Position (TP) sensor connectors
     
    Fuel injector electrical connectors
     
    Engine ground strap
     
    Exhaust manifold heat shield
     
    Front exhaust pipe from the manifold
     
    Exhaust manifold
     
    Coolant bypass pipe from the cylinder head
     
    Intake manifold support bracket
     
    Camshaft and Hydraulic Lash Adjusters (HLA-s)
     
    Cylinder head bolts in several steps, in the order illustrated
     
    Cylinder head bolts, then the cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-1.8L engine

     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.8L engine

  1. Thoroughly, clean the cylinder head and the block contact surfaces. Examine the head gasket and check the cylinder head for cracks. Check the cylinder head for warpage using a feeler gauge and straightedge. The maximum allowable distortion is 0.006 in. (0.15mm).
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Install or connect the following:

    New head gasket on the engine block
     
    Cylinder head
     
    Cylinder head bolts
     

  6.  
  7. Tighten the head bolts in the following step using the proper sequence:
    1. Step 1: Tighten to 36 ft. lbs. (49 Nm).
    2.  
    3. Step 2: Loosen the bolts in the reverse order shown.
    4.  
    5. Step 3: Tighten to 29 ft. lbs. (39 Nm).
    6.  
    7. Step 4: Tighten 90° ( 1 / 4 turn).
    8.  
    9. Step 5: Tighten 90° ( 1 / 4 turn).
    10.  

  8.  
  9. Install or connect the following:

    Camshaft and HLA-s
     
    Intake manifold support bracket and tighten the mounting bolts to 28-38 ft. lbs. (37-52 Nm)
     
    Coolant bypass pipe and tighten the mounting bolt to 66-86 ft. lbs. (89-117 Nm)
     
    Exhaust manifold, tighten the manifold-to-cylinder head mounting nuts to 28-34 ft. lbs. (38-46 Nm) and the manifold-to-exhaust pipe mounting nuts to 16-21 ft. lbs. (22-28 Nm)
     
    Exhaust manifold heat shield and tighten the mounting bolts to 13-22 ft. lbs. (19-30 Nm)
     

  10.  
  11. The remaining steps of the installation procedure is the reverse of the removal, while keeping in mind the following:

    Attach all hoses and connectors
     
    Fill the engine oil and coolant
     
    Start the vehicle and check for leaks
     

  12.  

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. Properly relieve the fuel system pressure.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Drain and recycle the engine oil.
  10.  
  11. Remove the upper radiator hose.
  12.  
  13. Remove the breather hose from the between the air cleaner and rocker arm (valve) cover.
  14.  
  15. Remove the air intake hose.
  16.  
  17. Disconnect the vacuum hose, fuel hose and coolant hose.
  18.  
  19. Disconnect the spark plug wires, tag before disconnecting.
  20.  
  21. Remove the ignition coil.
  22.  
  23. Remove the power steering pump and bracket and position aside. Do not disconnect the fluid lines.
  24.  
  25. Remove the intake manifold.
  26.  
  27. Remove the heat shield from the exhaust manifold.
  28.  
  29. Remove the exhaust manifold.
  30.  
  31. Remove the surge tank.
  32.  
  33. Remove the water pump and crankshaft pulleys.
  34.  
  35. Remove the timing belt cover, belt tensioner and timing belt.
  36.  
  37. Remove the cylinder head cover and cam carrier assembly.
  38.  
  39. Remove the cylinder head bolts, in several steps in the proper sequence.
  40.  
  41. Remove the cylinder head and gasket. Discard the gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening (loosen the reverse order)-1.5L and 1.6L (VIN 5) engines



    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head and related components-1.5L and 1.6L (VIN 5) engines

  42.  

To install:

  1. Thoroughly, clean the cylinder head and the block contact surfaces. Examine the head gasket and check the cylinder head for cracks. Check the cylinder head for warpage using a feeler gauge and straightedge. The maximum allowable distortion is 0.006 in. (0.15mm).
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Install a new head gasket on the engine block.
  6.  
  7. Install the cylinder head.
  8.  
  9. Install the cylinder head bolts.
  10.  
  11. Tighten the head bolts in the following step using the proper sequence:
    1. Step 1: Tighten to 36 ft. lbs. (49 Nm).
    2.  
    3. Step 2: Loosen the bolts in the reverse order shown.
    4.  
    5. Step 3: Tighten to 18 ft. lbs. (25 Nm).
    6.  
    7. Step 4: Tighten 90° ( 1 / 4 turn).
    8.  
    9. Step 5: Tighten 90° ( 1 / 4 turn).
    10.  

  12.  
  13. Install the timing belt tensioner pulley and timing belt. Make sure all timing marks are aligned.
  14.  
  15. Install the cylinder head cover. Tighten the bolts to 3.6-6.5 ft. lbs. (5-9 Nm).
  16.  
  17. Install the timing belt cover.
  18.  
  19. Install the intake manifold, with a new gasket. Torque the bolts to 11-14 ft. lbs. (15-20 Nm).
  20.  
  21. Install the exhaust manifold with a new gasket. Torque the bolts to 11-14 ft. lbs. (15-20 Nm).
  22.  
  23. Install the exhaust manifold heat shield.
  24.  
  25. Install the surge tank and tighten the bolts to 11-14 ft. lbs. (15-20 Nm).
  26.  
  27. Install the power steering pump and bracket.
  28.  
  29. Install the ignition coil and connect the spark plug wires.
  30.  
  31. Install the air intake hose.
  32.  
  33. Connect the vacuum hose, fuel hose and water hose.
  34.  
  35. Install the breather hose.
  36.  
  37. Fill the engine oil and coolant.
  38.  
  39. Start the vehicle and check for leaks.
  40.  

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.
  94.  
  95. Remove the OCV(Oil Control Valve) and filter.
  96.  
  97. Disconnect the water hose from water pipe.
  98.  
  99. Using 8mm and 10mm hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
  100.  
  101. Remove the 10 cylinder head bolts and plate washers.
  102.  
  103. Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-2.0L and 1.6L (VIN 3) engines

  104.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.0L and 1.6L (VIN 3) engines

  1. Install the cylinder head gasket onto the cylinder block. 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 an 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the proper sequence.
  6.  
  7. Tighten 2.0L engine as follows:
    1. Step 1: Tighten the M10 bolts to: 17-19.5 ft. lbs. (23-26.5 Nm)
    2.  
    3. Step 2: Tighten 60-65°.
    4.  
    5. Step 3: Tighten an additional 60-65°.
    6.  
    7. Step 4: Tighten the M12 bolts to: 20.5-23 ft. lbs. (27.5-31 Nm)
    8.  
    9. Step 5: Tighten 60-65°.
    10.  
    11. Step 6: Tighten an additional 60-65°.
    12.  

  8.  
  9. Tighten 1.6L (VIN 3) engine
  10.  
  11. Install the OCV filter along with a new filter gasket. Tighten the filter to 30-37 ft. lbs. (40-50 Nm).
  12.  
  13. Install the OCV. Tighten the bolt to 7-8.5 ft. lbs. (10-11.5 Nm).
  14.  
  15. Install the camshafts.
  16.  
  17. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.
  18.  
  19. Install the camshaft and bearing caps. Tighten the bearing cap bolts to 10.5 ft. lbs. (14 Nm).
  20.  
  21. Install the timing chain auto tensioner. Tighten the bolts to 6 ft. lbs. (8.5 Nm).
  22.  
  23. Remove the auto tensioner stopper pin.
  24.  
  25. Check and adjust valve clearance.
  26.  
  27. Using the SST (09221 - 21000), install the camshaft bearing oil seal.
  28.  
  29. Install the camshaft sprocket.
  30.  
  31. Install the cylinder head cover.
  32.  
  33. 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.
  34.  
  35. 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.
  36.  
  37. Install the PCV(Positive Crankcase Ventilation) hose.
  38.  
  39. Install the timing belt.
  40.  
  41. Install the intake manifold.
  42.  
  43. Install the exhaust manifold.
  44.  
  45. Install the spark plug cables.
  46.  
  47. Install the power steering pump bracket and bolts.
  48.  
  49. Install the power steering pump.
  50.  
  51. Connect the accelerator cable.
  52.  
  53. Install the brake booster hose.
  54.  
  55. Connect the hose of the PCSV side.
  56.  
  57. 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.
  58.  
  59. Connect the PCSV connector.
  60.  
  61. Connect the front heated oxygen sensor connector.
  62.  
  63. Connect the CKP connector.
  64.  
  65. Connect the oil pressure switch connector.
  66.  
  67. Connect the air conditioner compressor switch connector.
  68.  
  69. Connect the ground cables to intake manifold and vehicle's body.
  70.  
  71. Connect the knock sensor connector.
  72.  
  73. Connect the fuel injector connectors.
  74.  
  75. Connect the CMP connector.
  76.  
  77. Connect the ISA connector.
  78.  
  79. Connect the TPS connector.
  80.  
  81. Connect the ignition coil connector.
  82.  
  83. Connect the ECT connector.
  84.  
  85. Connect the oil temperature sensor connector.
  86.  
  87. Connect the OCV connector.
  88.  
  89. Install the heater hose.
  90.  
  91. Install the upper radiator hose and lower radiator hose.
  92.  
  93. Install the intake air hose and air cleaner assembly.
  94.  
  95. Install the air cleaner element.
  96.  
  97. Install the intake air hose and air cleaner upper cover.
  98.  
  99. Install the breather hose to intake air hose.
  100.  
  101. Connect the AFS connector.
  102.  
  103. Install the engine cover.
  104.  
  105. Install the heat shield and connect the battery terminals to the battery.
  106.  
  107. Fill with engine coolant.
  108.  
  109. Start the engine and check for leaks.
  110.  
  111. Recheck engine coolant level and oil level.
  112.  

1.8L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Drain and recycle the engine oil.
  10.  
  11. Remove the Positive Crankcase Ventilation (PCV) and crankcase ventilation hoses.
  12.  
  13. Disconnect the accelerator and, if equipped, the cruise control cables.
  14.  
  15. Disconnect the air intake hose from the throttle body.
  16.  
  17. Disconnect the brake vacuum hose and the purge control vacuum hose.
  18.  
  19. Remove the ventilation hose and fresh air duct.
  20.  
  21. Remove the upper radiator hose.
  22.  
  23. Disconnect the fuel hose from the fuel injector rail.
  24.  
  25. Remove the heater hoses.
  26.  
  27. Disconnect the Idle Air Control (IAC) and Throttle Position (TP) sensor connectors.
  28.  
  29. Disconnect the fuel injector electrical connectors.
  30.  
  31. Remove the engine ground strap.
  32.  
  33. Remove the exhaust manifold heat shield.
  34.  
  35. Remove the front exhaust pipe from the manifold.
  36.  
  37. Remove the exhaust manifold.
  38.  
  39. Remove the coolant bypass pipe from the cylinder head.
  40.  
  41. Remove the intake manifold support bracket.
  42.  
  43. Remove the camshaft and Hydraulic Lash Adjusters (HLA-s).
  44.  
  45. Remove the cylinder head bolts in several steps, in the order illustrated.
  46.  
  47. Remove the cylinder head bolts, then the cylinder head.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-1.8L engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.4L engine

  48.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-1.8L engine



Click image to see an enlarged view

Fig. Cylinder head torque sequence-2.4L engine

  1. Thoroughly, clean the cylinder head and the block contact surfaces. Examine the head gasket and check the cylinder head for cracks. Check the cylinder head for warpage using a feeler gauge and straightedge. The maximum allowable distortion is 0.006 in. (0.15mm).
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Install a new head gasket on the engine block.
  6.  
  7. Install the cylinder head.
  8.  
  9. Install the cylinder head bolts.
  10.  
  11. For 1.8L engines, tighten the head bolts in the following step using the proper sequence:
    1. Step 1: Tighten to 36 ft. lbs. (49 Nm).
    2.  
    3. Step 2: Loosen the bolts in the reverse order shown.
    4.  
    5. Step 3: Tighten to 29 ft. lbs. (39 Nm).
    6.  
    7. Step 4: Tighten 90° ( 1 / 4 turn).
    8.  
    9. Step 5: Tighten 90° ( 1 / 4 turn).
    10.  

  12.  
  13. For 2.4L engines, tighten the head bolts in the following step using the proper sequence:
    1. Step 1: Tighten to 14 ft. lbs. (20 Nm).
    2.  
    3. Step 2: Tighten 90° ( 1 / 4 turn).
    4.  
    5. Step 3: Loosen the bolts in the reverse order shown.
    6.  
    7. Step 4: Tighten to 14 ft. lbs. (20 Nm).
    8.  
    9. Step 5: Tighten 90° ( 1 / 4 turn).
    10.  
    11. Step 6: Tighten 90° ( 1 / 4 turn).
    12.  

  14.  
  15. Install the camshaft and HLA-s.
  16.  
  17. Install the intake manifold support bracket and tighten the mounting bolts to 28-38 ft. lbs. (37-52 Nm).
  18.  
  19. Install the coolant bypass pipe and tighten the mounting bolt to 66-86 ft. lbs. (89-117 Nm).
  20.  
  21. Install the exhaust manifold, tighten the manifold-to-cylinder head mounting nuts to 28-34 ft. lbs. (38-46 Nm) and the manifold-to-exhaust pipe mounting nuts to 16-21 ft. lbs. (22-28 Nm).
  22.  
  23. Install the exhaust manifold heat shield and tighten the mounting bolts to 13-22 ft. lbs. (19-30 Nm).
  24.  
  25. The remaining steps of the installation procedure is the reverse of the removal, while keeping in mind the following:
    1. Attach all hoses and connectors.
    2.  
    3. Fill the engine oil and coolant.
    4.  
    5. Start the vehicle and check for leaks.
    6.  

  26.  

2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Drain and recycle the engine oil.
  10.  
  11. Remove the upper radiator hose.
  12.  
  13. Remove the breather hose and air intake hose.
  14.  
  15. Remove the vacuum hose, fuel hose and coolant hose.
  16.  
  17. Remove the intake manifold.
  18.  
  19. Remove the spark plug wires from the spark plugs.
  20.  
  21. Remove the ignition coil.
  22.  
  23. Remove the upper and lower timing belt covers.
  24.  
  25. Remove the timing belt and camshaft sprockets.
  26.  
  27. Remove the heat protector and exhaust manifold.
  28.  
  29. Remove the water pump pulley and head cover.
  30.  
  31. Remove the intake and exhaust camshafts.
  32.  
  33. Remove the cylinder head bolts, loosening in the reverse of the torque sequence, in several steps.
  34.  
  35. Remove the cylinder head.
  36.  
  37. Remove the gaskets and discard.
  38.  

To install:

Click image to see an enlarged view

Fig. Cylinder head tightening sequence (use the reverse for removal)-2.7L engine

  1. Thoroughly, clean the cylinder head and the block contact surfaces. Examine the head gasket and check the cylinder head for cracks. Check the cylinder head for warpage using a feeler gauge and straightedge. The maximum allowable distortion is 0.006 in. (0.15mm).
  2.  
  3. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block.
  4.  
  5. Install the new head gasket on the engine block.
  6.  
  7. Install the cylinder head.
  8.  
  9. Install the cylinder head bolts.
  10.  
  11. Tighten the head bolts in the following step using the proper sequence:
    1. Step 1: Tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Step 2: Tighten 60° ( 1 / 6 turn).
    4.  
    5. Step 3: Tighten 45° ( 1 / 8 turn).
    6.  

  12.  
  13. The remainder of installation is the reverse or the removal procedure, noting the following steps:
    1. Attach all hoses and connectors.
    2.  
    3. Fill the engine oil and coolant.
    4.  
    5. Start the vehicle and check for leaks.
    6.  

  14.  

 
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