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Home >> Kia >> 2020 >> Soul GT Line Turbo >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Cylinder Head Assembly - 1.6L >> Valve Clearance Adjustment >> Valve Clearance Inspection And Adjustment

Valve Clearance Inspection And Adjustment

NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature: 20°C) and cylinder head is installed on the cylinder block.
  1. Remove the cylinder head cover.

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

  2. Set No. 1 cylinder to TDC/compression.
    1. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
      G13280372Courtesy 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 in the illustration. If not, turn the crankshaft one revolution (360°).
      G13280373Courtesy 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.
    G13280374Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the exhaust oil control valve (OCV) adaptor (A).
    G13280375Courtesy of KIA MOTORS AMERICA, INC.
  4. Inspect the valve clearance.
    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.
        G13280376Courtesy of KIA MOTORS AMERICA, INC.
      • 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.
    G13280377Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the engine mounting support bracket.
    1. Put a jack under the oil pan.
      G13280378Courtesy of KIA MOTORS AMERICA, INC.
      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).
      G13280379Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the engine mounting support bracket (A).
      G13280380Courtesy of KIA MOTORS AMERICA, INC.
    4. Lift the engine slightly using the jack to obtain space for releasing the timing chain tensioner.
  6. Adjust the intake and exhaust valve clearance.
    1. Remove the bolt (A) from the service hole in the timing chain cover.
      G13280381Courtesy of KIA MOTORS AMERICA, INC.
    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.

      G13280382Courtesy of KIA MOTORS AMERICA, INC.
      G13280383Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the camshaft bearing caps (A) with the order below.
      G13280384Courtesy of KIA MOTORS AMERICA, INC.
    4. With the pawl lifted, have a helper pull up the exhaust CVVT & camshaft (A) to allow the tensioner plunger (B) to retract.
      G13280385Courtesy of KIA MOTORS AMERICA, INC.
      G13280386Courtesy of KIA MOTORS AMERICA, INC.
    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.
      G13280387Courtesy of KIA MOTORS AMERICA, INC.
    6. Separate the exhaust camshaft (A) from the exhaust CVVT by removing the bolt.
      G13280388Courtesy of KIA MOTORS AMERICA, INC.
    7. Remove the exhaust CVVT (A) from the timing chain.
      G13280389Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the intake CVVT & camshaft (A).
      G13280390Courtesy of KIA MOTORS AMERICA, INC.
      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.
      G13280391Courtesy of KIA MOTORS AMERICA, INC.
    9. Remove the tappet(s) in out - of - specification valve clearance from the cylinder head.
      G13280392Courtesy of KIA MOTORS AMERICA, INC.
    10. Measure the thickness of the removed tappet using a micrometer.
      G13280393Courtesy of KIA MOTORS AMERICA, INC.
    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.
      G13280394Courtesy 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.
      G13280395Courtesy of KIA MOTORS AMERICA, INC.
    16. Install the exhaust camshaft (A) to the exhaust CVVT.
      G13280396Courtesy of KIA MOTORS AMERICA, INC.
    17. Remove the pick from the service hole in the timing chain cover.
      G13280397Courtesy of KIA MOTORS AMERICA, INC.
    18. Check that each timing mark of the intake and exhaust CVVT sprockets is aligned as shown in the picture.
      G13280398Courtesy of KIA MOTORS AMERICA, INC.
    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)

      G13280399Courtesy of KIA MOTORS AMERICA, INC.
    20. Install the engine mounting support bracket.
      1. Install the engine mounting support bracket (A).

        Tightening torque 

        Nut (B):

        78.5 - 98.1 N.m (8.0 - 10.0 kgf.m, 57.9 - 72.3 lb.ft)

        Bolt and Nuts (C):

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

        G13280400Courtesy of KIA MOTORS AMERICA, INC.
      2. Install the engine ground cable (A).
        G13280401Courtesy of KIA MOTORS AMERICA, INC.
      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)

      G13280402Courtesy 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.
      G13280403Courtesy 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)

      G13280404Courtesy of KIA MOTORS AMERICA, INC.
    25. Install the cylinder head cover.

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

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