Kia Forte: Cylinder Head Assembly / Cylinder Head

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.

Mark all wiring and hoses to avoid misconnection.

Turn the crankshaft damper pulley so that the piston of No. 1 cylinder is at TDC (top dead center) on compression stroke.

Tightening torque

Hose clamp bolt :

4.9 - 6.9 N·m (0.5 - 0.7 kgf·m, 3.6 - 5.1 lb·ft, 43.4 - 60.8 lb·in)

(If equipped with a cap, tighten it until the cap is removed.)

Pipe mounting Bolt :

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

Tightening torque :

4.9 - 6.8 N·m (0.5 - 0.7 kgf·m, 3.6 - 5.0 lb·ft, 43.4 - 60.8 Ib·in)

Tightening torque :

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

When removing the CVVT assembly bolt, fix the camshaft (A) using a wrench.

Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.

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

Lift the cylinder head from the cylinder block and put the cylinder head on wooden blocks.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

Remove the cylinder head gasket (B).

When removing MLAs, mark all the MLAs for their rearrangement.

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

Remove the spring retainer.

Remove the spring.

Remove the valve.

Remove the valve stem seal.

Using a magnetic pickup tool, remove the spring seat.

Do not reuse the valve stem seals.

Flatness of cylinder head gasket surface

Standard :

Less than 0.05 mm (0.0020 in) for total area

Less than 0.02 mm (0.0008 in) for a section of 100 mm (3.9370 in) X 100 mm (3.9370 in)

Using a caliper gauge, measure the inner diameter of valve guide.

For valve guide inner diameter, evenly measure 5 points 2 mm (0.0787 in) from each end of valve guide.

Using a micrometer, measure the outer diameter of valve stem.

Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.

If the clearance is greater than specification, replace the valve or the cylinder head.

Check the valve is ground to the correct valve face angle.

Check that the surface of valve for wear. If the valve face is worn, replace the valve.

Check the valve head margin thickness.

If the margin thickness is less than minimum, replace the valve.

Check the length of valve.

Check the surface of valve stem tip for wear. If the valve stem tip is worn, replace the valve.

Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head.

Check the valve guide for wear. If the valve guide is worn, replace the cylinder head.

Using a steel square, measure the out - of - square of valve spring.

Using a vernier calipers, measure the free length of valve spring.

Thoroughly clean all parts to be assembled.

Before installing the parts, apply fresh engine oil to all sliding and rotating surface.

Replace oil seals with new ones.

Install the spring seats.

Using the SST (09222-2B100), push in a new oil seal.

• Do not reuse old valve stem oil seals. • Incorrect installation of the seal could result in oil leakage past the valve guides. • Intake valve stem seals are different from exhaust ones in type. Do not reassembly ones in the other's places.

Install the valve, valve spring and spring retainer, after applying engine oil at the end of each valve.

When installing valve springs, the enamel coated side should face the valve spring retainer.

When installing the SST, use the torque, 1.2kgf.m or less.

All the MLAs must be installed in its original position.

Thoroughly clean all parts to be assembled.

Always use new cylinder head gasket and manifold gaskets.

Always use new cylinder head bolts. Cylinder head bolts are torque - to - yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.

The cylinder head gasket is a metal gasket. Take care not to bend it.

Rotate the crankshaft, set the No.1 piston at TDC.

Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.

Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.

Refer to the illustration for applying sealant.

After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes.

Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.

Always use new cylinder head bolts. Cylinder head bolts are toque - to - yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.

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)

Tightening torque :

63.7 - 73.5 N·m (6.5 - 7.5 kgf·m, 47.0 - 54.2 lb·ft)

When installing the CVVT assembly, fix the cam shaft using wrench.

Tightening torque :

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

Tightening torque :

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