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Kia Sportage: Cylinder Head | Removal - Repair procedures - Cylinder Head

Kia Sportage Third generation (SL) - (2011-2016) - Service and Repair Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head | Removal - Repair procedures - Cylinder Head

Components and Components Location

 Components

  1. Camshaft bearing cap
  2. Camshaft front bearing cap
  3. Exhaust camshaft
  4. Intake camshaft
  5. Exhaust CVVT assembly
  6. Intake CVVT assembly
  7. Exhaust camshaft upper bearing
  8. Exhaust camshaft lower bearing
  9. MLA
  10. Retainer lock
  11. Retainer
  12. Valve spring
  13. Valve stem seal
  14. Valve
  15. Cylinder head
  16. Cylinder head gasket
  17. Fuel pump bracket

Removal - Repair procedures - Cylinder Head

Removal

CAUTION

  • 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.

WARNING

In case of removing the high pressure fuel рumр, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

1. Remove the engine cover.

2. Disconnect the battery negative terminal (A).

3. Remove the air cleaner assembly and the intercooler inlet/outlet hoses.

3. Remove the air cleaner assembly and the intercooler inlet/outlet hoses. (Refer to Engine and transaxle assembly in this group)

4. Remove the RH front wheel.

5. Remove the under cover.

6. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. (Refer to Cooling system in this group)

7. Disconnect the radiator upper hose (A) and lower hose (B).

8. Disconnect the wiring connectors and harness clamps, and remove the wiring

8. Disconnect the wiring connectors and harness clamps, and remove the wiring protectors from the cylinder head, intake manifold and exhaust manifold.

  1. Disconnect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B).

  1. Disconnect the А/С compressor switch connector (A), the alternator connector (B), the OPS (Oil pressure switch) connector & injector extension connector (C), the knock sensor connector (D), the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (E), the ETC (Electronic throttle control) connector (F) and the vacuum pump connector (G).

  1. Disconnect the ignition coil connectors (B) and the fuel pump connector (A).

  1. Disconnect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C).

  1. Disconnect the intake CMPS (Camshaft position sensor) connector (A), the PCSV (Purge control solenoid valve) connector (B), the ECTS (Engine coolant temperature sensor) connector (C), the condenser connector (D), the CKPS (Crankshaft position sensor) connector (E), the exhaust CMPS (Camshaft position sensor) connector (F) and the electric wastegate actuator connector (G).

9. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose

9. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).

10. Remove the vacuum pipe assembly (A).

10. Remove the vacuum pipe assembly (A).

11. Remove the high pressure pipe (A). (Refer to FL group)

11. Remove the high pressure pipe (A). (Refer to FL group)

12. Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer

12. Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to FL group)

13. Disconnect the heater hoses (A).

13. Disconnect the heater hoses (A).

14. Disconnect the throttle body coolant hoses (A).

14. Disconnect the throttle body coolant hoses (A).

15. Disconnect the oil cooler coolant hoses (A).

15. Disconnect the oil cooler coolant hoses (A).

16. Remove the water temperature control assembly (A) with the water inlet

16. Remove the water temperature control assembly (A) with the water inlet pipe (B).

17. Remove the timing chain. (Refer to Timing system in this group)

17. Remove the timing chain. (Refer to Timing system in this group)

18. Remove the intake and exhaust manifold. (Refer to Intake and exhaust system in this group)

19. Remove the high pressure fuel pump bracket (A).

20. Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B).

20. Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B).

NOTE

NOTE

When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.

21. Remove the camshaft.

21. Remove the camshaft.

  1. Remove the front camshaft bearing cap (A) with the upper bearing (B).

  1. Remove the camshaft bearing cap (A) in the sequence shown.

  1. Remove the camshafts (A).

  1. Remove the exhaust camshaft lower bearing (A).

22. Remove the intake OCV (Oil control valve) (A) using a torx wrench and the

22. Remove the intake OCV (Oil control valve) (A) using a torx wrench and the OTS (Oil temperature sensor) (B).

23. Remove the exhaust OCV (Oil control valve) (A) using a torx wrench.

23. Remove the exhaust OCV (Oil control valve) (A) using a torx wrench.

24. Remove the intake CMPS (Camshaft position sensor) (A).

24. Remove the intake CMPS (Camshaft position sensor) (A).

25. Remove the exhaust CMPS (Camshaft position sensor) (A) after removing the

25. Remove the exhaust CMPS (Camshaft position sensor) (A) after removing the engine hanger (B).

26. Remove the injector & rail module (A). (Refer to FL group)

26. Remove the injector & rail module (A). (Refer to FL group)

27. Remove the cylinder head.

27. Remove the cylinder head.

  1. Using triple square wrench, 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

CAUTION

Head warpage or cracking could result from removing bolts in an incorrect order.

  1. Lift the cylinder head (A) from the dowels on the cylinder block and place 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.

  1. Remove the cylinder head gasket (B).

Disassembly

Disassembly

NOTE

Identify MLA (Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position.

1. Remove the MLAs (A).

2. Remove the valves.

2. Remove the valves.

  1. Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.

  1. Remove the spring retainer.
  2. Remove the valve spring.
  3. Remove the valve.
  4. Using needle-nose pliers, remove the valve stem seal.

NOTE

Do not reuse old valve stem seals.

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