Repair Procedures: Installation: Notes

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.

Install the cylinder head.
1. The sealant locations on cylinder head and cylinder block must be free from contamination.
2. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Fig 1: Identifying Sealant Location
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Refer to Fig 2 to apply the sealant.
  
  Bead width : 2.0~3.0 mm
  
  Sealant locations : 1.0~1.5mm from block surface
  
  Recommended sealant : Liquid sealant TB1217H
  
  Fig 2: Identifying Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
3. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Fig 3: Identifying Sealant On Cylinder Head Gaskets
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Be careful of the installation direction.
  
  Fig 4: Identifying Mark
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the cylinder head.
  NOTE: Remove the extruded sealant after assembling cylinder heads.
  
  Fig 5: Identifying Cylinder Head
  Courtesy of KIA MOTORS AMERICA, INC.
Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
Install cylinder head bolts.
1. Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
2. Using SST (09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
  Tightening torque
  
  Head bolt : 37.3~41.2Nm (3.8~4.2kgf.m, 27.5~30.4lb-ft) + 118~122° + 88~92°
  
  Bolt (A) : 18.62~23.52Nm (1.9~2.4kgf.m, 13.74~17.36lb-ft)
  
  NOTE: Always use new cylinder head bolt.
  
  Fig 6: Cylinder Head Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 7: Identifying Bolt
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 8: Installing Cylinder Head Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
Install the CVVT and camshaft sprocket.
Tightening torque

64.68 ~ 76.44Nm (6.6 ~ 7.8 kgf.m, 47.74 ~ 56.4lb-ft)

Fig 9: Identifying CVVT And Camshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Install camshaft-inlet to dowel pin of CVVT assembly.
  Ensure that the camshaft oil inlet is not obstructed.
- Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
- Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
Install camshafts (A).
NOTE:
- Apply a light coat of engine oil on camshaft journals.
- Assemble the key groove of camshaft rear side to the same level of head top surface.
- Ensure that the camshaft components are installed in the correct locations.
  
  Fig 10: Identifying Camshafts
  Courtesy of KIA MOTORS AMERICA, INC.