Valve Clearance Inspection And Adjustment

(Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")

1. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
   Fig 1: Aligning Crankshaft Pulley Groove With Timing Mark Of Timing Chain Cover

   Courtesy of KIA MOTORS AMERICA, INC.
2. Check that the marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface as shown below. If not, turn the crankshaft one revolution (360°).
   Fig 2: Locating Marks Of Intake And Exhaust CVVT Sprockets

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Do not turn the crankshaft damper pulley counterclockwise.
3. Mark the timing chain links corresponding to the timing marks on the CVVT sprockets with a indelible marker.

Fig 3: Locating Marked Timing Chain Links

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1. Check only the intake valves of the 1st and 2nd cylinders and exhaust valves of the 1st and 3rd cylinders for their clearance.
   • Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
   Fig 5: Inspecting Valve Clearance (Intake Valves Of 1St And 2Nd Cylinders And Exhaust Valves Of 1St And 3Rd Cylinders)

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   • Record the out - of - specification valve clearance measurements. They will be used later to determine the required tappet for adjusting.

   Valve clearance specification (Engine coolant temperature: 20°C [68°F])

   Limit

   Intake: 0.17 - 0.23 mm (0.0067 - 0.0091 in.)

   Exhaust: 0.32 - 0.38 mm (0.0126 - 0.0150 in.)

2. Turn the crankshaft pulley one revolution (clockwise 360°) and align its groove with timing mark of the timing chain cover.
3. Check the intake valves of the 3rd and 4th cylinders and exhaust valves of the 2nd and 4th cylinders for their clearance.

Fig 6: Inspecting Valve Clearance (Intake Valves Of 3Rd And 4Th Cylinders And Exhaust Valves Of 2Nd And 4Th Cylinders)

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1. Put a jack under the oil pan.
   Fig 7: Placing Jack Under Oil Pan

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   NOTE: Place a wooden block between the jack and the oil pan to prevent damage to the oil pan.
2. Remove the engine ground cable (A).
   Fig 8: Removing Engine Ground Cable

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3. Remove the engine mounting support bracket (A).
   Fig 9: Removing Engine Mounting Support Bracket

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4. Lift the engine slightly using the jack to obtain space for releasing the timing chain tensioner.

1. Remove the bolt (A) from the service hole in the timing chain cover.
   Fig 10: Locating Timing Chain Cover Service Hole Bolt

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2. Lock the timing chain tensioner in the fully retracted position.

   Insert a pick into the service hole in the timing chain cover and lower the hole in the left side of the ratchet plate (A) on the tensioner to allow the pawl (B: located inside the tensioner behind the ratchet plate) to be lifted.

   Fig 11: Lowering Hole In Left Side Of Ratchet Plate With Pick

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   Fig 12: Lifting Pawl

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3. Remove the camshaft bearing caps (A) with the order below.
   Fig 13: Camshaft Bearing Caps Removal Order

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4. With the pawl lifted, have a helper pull up the exhaust CVVT & camshaft (A) to allow the tensioner plunger (B) to retract.
   Fig 14: Pulling Up Exhaust CVVT And Camshaft

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   Fig 15: Locating Tensioner Plunger

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5. With the tensioner plunger in the fully retracted position, raise the hole in the left side of the ratchet plate (A) again through the service hole in the chain cover to align the ratchet plate hole with the hole in the tensioner body behind the ratchet plate, then lock the tensioner by inserting the pick through the ratchet plate and tensioner body holes.
   Fig 16: Raising Hole In Left Side Of Ratchet Plate Through Service Hole Of Chain Cover

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6. Separate the exhaust camshaft (A) from the exhaust CVVT by removing the bolt.
   Fig 17: Locating Exhaust Camshaft

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7. Remove the exhaust CVVT (A) from the timing chain.
   Fig 18: Locating Exhaust CVVT

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8. Remove the intake CVVT & camshaft (A).
   Fig 19: Locating Intake CVVT And Camshaft

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   NOTE: Fasten the timing chain to the engine hanger with a cable tie or strap not to allow the timing chain to fall down when removing the intake CVVT & camshaft.
   Fig 20: Fastening Timing Chain To Engine Hanger With Cable Tie Or Strap

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9. Remove the tappet(s) in out - of - specification valve clearance from the cylinder head.
   Fig 21: Cylinder Head

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10. Measure the thickness of the removed tappet using a micrometer.
    Fig 22: Measuring Thickness Of Tappet Using Micrometer

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11. Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

    Valve clearance (Engine coolant temperature: 20°C)

    T: Thickness of removed tappet

    A: Measured valve clearance

    N: Thickness of new tappet

    Intake: N = T + [A - 0.20 mm (0.0079 in.)]

    Exhaust: N = T + [A - 0.25 mm (0.0098 in.)]

12. Select a new tappet with a thickness as close as possible to the calculated value.
    NOTE: Shims are available in 41 size increments of 0.015 mm (0.0006in.) from 3.00 mm (0.118in.) to 3.690 mm (0.1417 in.)
13. Place a new tappet on the cylinder head.
14. Install the intake CVVT & camshaft (A), with the timing mark on the intake CVVT sprocket aligned with the mark (painted link) on the timing chain.
    Fig 23: Locating Intake CVVT And Camshaft With Timing Mark

    Courtesy of KIA MOTORS AMERICA, INC.
15. Install the exhaust CVVT (A), with the timing mark on the exhaust CVVT sprocket aligned with the mark (painted link) on the timing chain.
    Fig 24: Locating Exhaust CVVT With Timing Mark

    Courtesy of KIA MOTORS AMERICA, INC.
16. Install the exhaust camshaft (A) to the exhaust CVVT.
    Fig 25: Installing Exhaust Camshaft To Exhaust CVVT

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17. Remove the pick from the service hole in the timing chain cover.
    Fig 26: Removing Pick From Service Hole Of Timing Chain Cover

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18. Check that each timing mark of the intake and exhaust CVVT sprockets is aligned as shown below.
    Fig 27: Locating Timing Mark Of Intake And Exhaust CVVT Sprockets

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19. Install the bolt (A) to the service hole in the timing chain cover.

    Tightening torque: 

    27.5 - 30.4 N.m (2.8 - 3.1 kgf.m, 20.3 - 22.4 lb.ft)

    Fig 28: Locating Timing Chain Cover Service Hole Bolt

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20. Install the engine mounting support bracket.
    1. Install the engine mounting support bracket (A).

       Tightening torque 

       Nut (B):

       88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb.ft)

       Bolt and Nuts (C):

       58.8 - 73.5 N.m (6.0 - 7.5 kgf.m, 43.4 - 54.2 lb.ft)

       Fig 29: Installing Engine Mounting Support Bracket

       Courtesy of KIA MOTORS AMERICA, INC.
       NOTE: Always use a new nuts.
    2. Install the engine ground cable (A).
       Fig 30: Installing Engine Ground Cable

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    3. Remove the jack from the oil pan.
21. Install the camshaft bearing caps with the order below.

    Tightening torque 

    M6 bolts:

    11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb.ft)

    M8 bolts:

    18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb.ft)

    Fig 31: Camshaft Bearing Caps Installation Order

    Courtesy of KIA MOTORS AMERICA, INC.
22. Turn the crankshaft two turns in the operating direction (clockwise) and check that the marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface.
    Fig 32: Locating Marks Of Intake And Exhaust CVVT Sprockets

    Courtesy of KIA MOTORS AMERICA, INC.
23. Recheck the valve clearance.

    Valve clearance (Engine coolant temperature: 20°C) 

    [Specification]

    Intake: 0.17 - 0.23 mm (0.0067 - 0.0091 in.)

    Exhaust: 0.22 - 0.28 mm (0.0087 - 0.0110 in.)

24. Install the exhaust oil control valve (OCV) adaptor (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)

    Fig 33: Installing Exhaust Oil Control Valve Adaptor

    Courtesy of KIA MOTORS AMERICA, INC.
25. Install the cylinder head cover.

    (Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")