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Home >> Kia >> 2023 >> Sorento Plug-In Hybrid SX Prestige >> Repair and Diagnosis >> External Pages >> Different car >> Section 116 (Cylinder Head Assembly (PHEV)) >> Cylinder Head >> Repair Procedures >> Installation

Repair Procedures: Installation

WARNING: This page is about a different car, the 2024 Kia Sorento. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • Thoroughly clean all parts to be assembled.
  • Always use new cylinder head gasket and manifold gaskets.
  • Always use a new cylinder head bolt.
  • The cylinder head and exhaust manifold is a metal gasket. Take care not to bend it.
  • Turn the crankshaft pulley so that the No. 1 piston is at top dead center
  • Clean the gasket contact surfaces of the cylinder head and cylinder block to prevent oil, dirt and scratches.
  1. Install the cylinder head.
    1. Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the cylinder block and the cylinder head.
    2. Apply liquid sealant on the upper surface of the cylinder block.

      Width: 2.0 - 3.0 mm (0.0787 - 0.1181 in.)

      Sealant: MS721 - 40 TYPE AA or AAO

      G14937065Courtesy of KIA MOTORS AMERICA, INC.
    3. Install the cylinder head gasket (A) to the cylinder block.
      G14937066Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Be careful not to change the installation direction of the gasket.
    4. Apply liquid sealant on the upper surface of the cylinder head gasket.

      Width: 2.0 - 3.0 mm (0.0787 - 0.1181 in.)

      Sealant: MS721 - 40 TYPE AA or AAO

      G14937067Courtesy of KIA MOTORS AMERICA, INC.
    5. Place the cylinder head (A) carefully not to damage the head gasket.
    G14937068Courtesy of KIA MOTORS AMERICA, INC.
  2. Install the new cylinder head bolts.
    1. Do not apply engine oil on the new cylinder head bolts.
    2. Recheck tightening torque 29.4 N.m (3.0 kgf.m, 21.7 lb.ft) of each cylinder head bolt, after installing a new plain washer and a new cylinder head bolt according to the tightening torque 29.4 N.m (3.0 kgf.m, 21.7 lb.ft) in procedure down below. Continuously tighten with angle tightening torque (90°) following the procedure in picture below after tightening with angle tightening torque (90°) with no stop following the procedure down below.

      Tightening torque: 

      Step 1: 29.4 N.m (3.0 kgf.m, 21.7 lb.ft) + 90° + 90°

      Step 2: 90°

      Step 3: 90°

      Fig 1: Cylinder Head Bolts Tightening Sequence
      G14937069Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • Always use a new cylinder head bolt and cylinder head bolt washer.
      • Assemble the cylinder head gasket and cylinder head within 5 minutes after applying liquid sealant.
      • Remove the extruded sealant within 5 minutes after installing cylinder head bolts.
      • When installing the cylinder head bolt, make sure where up/down direction of the cylinder head bolt washer part is headed and check if the chamber and round part of the washer is facing the head of the cylinder head bolt.
        G14937070Courtesy of KIA MOTORS AMERICA, INC.
      • Use decagonal driver socket that has under 15 mm (0.5906 in.) external diameter and longer than 75 mm (2.9528 in.) cylinder to not have interference between cylinder head and decagonal driver socket when the cylinder head bolt installation.
        G14937071Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Deformation of the cam carrier contact surface during interference between the cylinder head bolt mounting tool and the cylinder head may cause instability in the rotation of the camshaft.
  3. Install the hydraulic lash adjuster (HLA) (A).
    G14937072Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the rear engine hangers (A).

    Tightening torque: 

    18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

    G14937073Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the cam carrier to the cylinder head.
    1. Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the bottom surface of the cam carrier and top surface of the cylinder head.
    2. Apply a liquid gasket to the face of the cam carrier without breaking as shown below.

      Width: 2.5 - 3.5 mm (0.0984 - 0.1378 in.)

      Sealant: MS721 - 40 AA or AAO

      G14937074Courtesy of KIA MOTORS AMERICA, INC.
    3. Install the cam carrier accurately with respect to the dowel pin of the cam carrier and the hole on the top of the cylinder head.
      NOTE: When installing the cam carrier to the cylinder head, make sure to prevent the sealant from entering the hole of the oil level gauge (A) and the positive crankcase ventilation (PCV) (B) and high pressure fuel pump bracket mounting hole (C).
      G14937075Courtesy of KIA MOTORS AMERICA, INC.
    4. Install the cam carrier (A).

      Tightening torque:

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

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

      G14937076Courtesy of KIA MOTORS AMERICA, INC.
      G14937077Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • Assemble the cam carrier within 5 minutes after applying sealant.
      • Assemble the camshaft bearing cap within 5 minutes after assembling the cam carrier.
      • The engine running or pressure test should not be performed within 30 minutes after assembling the cam carrier.
      • After installing the cam carrier to the cylinder head, check whether there are sealants in the hole of the oil level gauge and the positive crankcase ventilation (PCV).
      • After fitting the cam carrier to the cylinder head, make sure that the swing arm is dislodged and installed normally.
  6. Install the turbocharger water outlet hose and pipe (A).

    Tightening torque: 

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

    G14937078Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: If the O-ring is not inserted vertically into the head processing hole during degaussing pipe (A) assembly, damage caused by O-ring chewing may result.
  7. Install the cylinder head heat protector (A).

    Tightening torque: 

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

    G14937079Courtesy of KIA MOTORS AMERICA, INC.
  8. Install the heater pipe mounting bolt (A).

    Tightening torque: 

    14.7 - 21.6 N.m (1.5 - 2.2 kgf.m, 10.8 - 15.9 lb.ft)

    G14937080Courtesy of KIA MOTORS AMERICA, INC.
  9. Install the intake and exhaust CVVT And camshaft.

    (Refer to Cylinder Head Assembly - "CVVT And CAMSHAFT ")

  10. After installing the exhaust camshaft and CVVD assembly, make sure that the swing arm is dislodged and installed normally.
  11. Install the camshaft front bearing cap and camshaft bearing cap.
    NOTE:
    • If engine oil is sufficiently attached to the camshaft front bearing cap and the camshaft bearing cap mounting bolts and bolt holes, tighten to the lower limit of the tightening torque standard.
    • Apply engine oil to the top of the intake and exhaust camshaft journals, and then install the camshaft front bearing cap and camshaft bearing cap
    1. Install the camshaft front bearing cap (A) and the intake and exhaust camshaft bearing cap (B).
    G14937081Courtesy of KIA MOTORS AMERICA, INC.
  12. Install the other parts reverse order of removal.
  13. Fill with coolant.

    (Refer to Cooling System - "ENGINE COOLANT and HYBRID COOLING SYSTEM COOLANT ")

    NOTE: The cooling water is injected according to the integrated flow control valve (ITM) cooling water filling method.
  14. Fill with engine oil.

    (Refer to Lubrication System - "ENGINE OIL ")

  15. Connect the KDS.
  16. Select the "CVVD intake adaptation" in the vehicle S/W management.
G14937082Courtesy of KIA MOTORS AMERICA, INC.
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