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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 >> Removal

Repair Procedures: Removal

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.
CAUTION: In case of removing the high pressure fuel pump, 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.
NOTE:
  • Use fender covers to avoid damaging painted surfaces.
  • To avoid damaging the cylinder head, wait until the engine cools down to room temperature before removing the cylinder head.
  • When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
  • Carefully disconnect the connector to prevent damage.

Information 

Mark all wiring and hoses to avoid misconnection.

  1. Disconnect the battery negative terminal.

    (Refer to Engine Electrical System - "AUXILIARY BATTERY ")

  2. Shut off the high voltage circuit.

    (Refer to General Information - "HIGH VOLTAGE SHUT-OFF PROCEDURES ")

  3. Remove the engine cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE COVER ")

  4. Remove the engine room under cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")

  5. Drain the engine oil.

    (Refer to Lubrication - "ENGINE OIL ")

  6. Drain the engine coolant.

    (Refer to Cooling System - "COOLANT ")

  7. Drain the inverter coolant.

    (Refer to Hybrid Motor System - "COOLANT ")

  8. Remove the air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  9. Disconnect the intercooler inlet hose (A).
    G14937039Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the radiator upper hose (A).
    G14937040Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the radiator lower hose (A).
    G14937041Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the heater hose (A).
    G14937042Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the oil level gauge.

    (Refer to Lubrication System - "OIL LEVEL GAUGE ")

  14. Remove the engine control module (ECM).

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  15. Remove the hybrid power control unit (HPCU).

    (Refer to Hybrid Control System - "HYBRID POWER CONTROL UNIT (HPCU) ")

  16. Remove the intake manifold.

    (Refer to Intake and Exhaust System - "INTAKE MANIFOLD ")

  17. Remove the delivery pipe.

    (Refer to Engine Control/Fuel System - "DELIVERY PIPE ")

  18. Remove the front muffler.

    (Refer to Intake and Exhaust System - "MUFFLER ")

  19. Remove the EGR cooler.

    (Refer to Intake and Exhaust System - "EGR COOLER ")

  20. Remove the turbo manifold module.

    (Refer to Intake and Exhaust System - "TURBO MANIFOLD MODULE ")

  21. Remove the cylinder head cover.

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

  22. Remove the active purge pump.

    (Refer to Evaporative Emission Control System - "ACTIVE PURGE PUMP ")

  23. Remove the integrated thermal management module (ITM).

    (Refer to Cooling System - "INTEGRATED THERMAL MANAGEMENT MODULE (ITM) ")

  24. Remove the heater pipe mounting bolts (A).
    G14937043Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the timing chain cover.

    (Refer to Timing System - "TIMING CHAIN COVER ")

  26. Remove the timing chain.

    (Refer to Timing System - "TIMING CHAIN ")

  27. Remove the intake and exhaust CVVT And camshaft.

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

  28. Remove the cylinder head cover heat protector (A).
    G14937044Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the turbocharger water outlet hose and pipe (A).
    G14937045Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the cam carrier mounting bolts (A).
    G14937046Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the cam carrier (A).
    G14937047Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the rear engine hangers (A).
    G14937048Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the hydraulic lash adjuster (HLA) (A).
    G14937049Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the cylinder head bolts and remove the cylinder head.
  1. Using a socket, divide the cylinder head bolts 2-3 times in the sequence shown below
    Fig 1: Cylinder Head Bolts Loosening Sequence
    G14937050Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Removing cylinder head bolts in an incorrect order may result in head warpage or crack.
    • 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 removal.
    G14937051Courtesy of KIA MOTORS AMERICA, INC.
  2. Lift the cylinder head (A) from the cylinder block and put the cylinder head on wooden blocks.
    G14937052Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
  3. Remove the cylinder head gasket (A).
G14937053Courtesy of KIA MOTORS AMERICA, INC.
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