Kia Sedona: Cylinder Head Repair procedures

Third generation YP (2014-2024) / Kia Sedona YP Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head Repair procedures

Removal

•	Use fender covers to avoid damaging painted surfaces.

•	To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature (20°C [68°F]) 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 pulley so that the No. 1 piston is at top dead center.

[RH Cylinder Head]

1.	Remove the air duct. (Refer to Intake And Exhaust System - "Air Cleaner")

2.	Remove the battery. (Refer to Engine Electrical System - "Battery")

3.	Remove the engine cover. (Refer to Engine And Transaxle Assembly - "Engine Cover")

4.	Remove the air cleaner assembly. (Refer to Intake And Exhaust System - "Air Cleaner")

5.	Remove the engine room under cover. (Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")

6.	Drain the engine coolant. (Refer to Cooling System - "Coolant")

7.	Disconnect the radiator upper hoses (A) and radiator lower hose (B).

8.	Disconnect the control wiring harness connectors and fasteners and remove the wiring harness protectors from the RH cylinder head and surge tank.

9.	Remove the surge tank. (Refer to Intake And Exhaust System - "Surge Tank")

10.	Remove the intake manifold. (Refer to Intake And Exhaust System - "Intake Manifold")

11.	Remove the RH exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

12.	Remove the power steering oil pump. (Refer to Steering System - "Power Steering Oil Pump")

13.	Remove the RH cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")

14.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

15.	Remove the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

16.	Remove the RH camshaft. (Refer to Cylinder Head Assembly - "Camshaft")

17.	Remove the delivery pipe. (Refer to Engine Control / Fuel System - "Delivery Pipe")

18.

Remove the RH cylinder head.

(1)	Remove the RH cylinder head rear bolt (A).

(2)

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

Removing bolts in an incorrect order may result in head warpage or crack.

(3)

Lift the RH cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks of a bench.

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

(4)	Remove the RH cylinder head gasket.

[LH Cylinder Head]

1.	Remove the air duct. (Refer to Intake And Exhaust System - "Air Cleaner")

2.	Remove the battery. (Refer to Engine Electrical System - "Battery")

3.	Remove the engine cover. (Refer to Engine And Transaxle Assembly - "Engine Cover")

4.	Remove the air cleaner assembly. (Refer to Intake And Exhaust System - "Air Cleaner")

5.	Remove the engine room under cover. (Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")

6.	Drain the engine coolant. (Refer to Cooling System - "Coolant")

7.	Disconnect the radiator upper hoses (A) and radiator lower hose (B).

8.	Disconnect the control wiring harness connectors and fasteners and remove the wiring harness protectors from the RH cylinder head and surge tank.

9.	Remove the surge tank. (Refer to Intake And Exhaust System - "Surge Tank")

10.	Remove the intake manifold. (Refer to Intake And Exhaust System - "Intake Manifold")

11.	Remove the LH exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

12.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

13.	Remove the LH cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")

14.	Remove the timing chain. (Refer to Timing System - "Timing Chain")

15.	Remove the water temperature control assembly. (Refer to Cooling System - "Water Temperature Control Assembly")

16.	Remove the LH camshaft. (Refer to Cylinder Head Assembly - "Camshaft")

17.	Remove the delivery pipe. (Refer to Engine Control / Fuel System - "Delivery Pipe")

18.

Remove the LH cylinder head.

(1)

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

Removing bolts in an incorrect order may result in head warpage or crack.

(2)

Lift the LH cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks of a bench.

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

(3)	Remove the LH cylinder head gasket.

Disassembly

Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original position.

1.	Remove the MLAs (A).

Remove the valves.

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

(2)	Remove the spring retainer.

(3)	Remove the valve spring.

(4)	Remove the valve.

(5)	Using the SST (09222-29000), remove the valve stem seal.

Do not reuse old valve stem seals.

3.	Remove the LH/RH intake camshaft OCV (A).

Inspection

Cylinder Head

Inspect for flatness.

Using a precision straight edge and feeler gauge, measure the warpage of the surface contacting with the cylinder block

Flatness of cylinder head gasket surface

Standard : Less than 0.05 mm (0.002 in.)

[Less than 0.02 mm(0.0008 in.) / 150x150]

Flatness of manifold gasket surface

Standard : Less than 0.03 mm (0.001 in) / 110x110

2.	Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

Valve And Valve Spring

Inspect valve stems and valve guides.

(1)

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

Valve guide I.D.

Intake / Exhaust : 5.500 ~ 5.512 mm (0.216 ~ 0.217 in.)

(2)

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

Valve stem O.D.

Intake : 5.465 ~ 5.480 mm (0.2151 ~ 0.2157 in.)

Exhaust : 5.458 ~ 5.470 mm (0.2149 ~ 0.2153 in.)

(3)

Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

Valve stem-to-guide clearance

[Standard]

Intake : 0.020 ~ 0.047 mm (0.0008 ~ 0.0018 in.)

Exhaust : 0.030 ~ 0.054 mm (0.0012 ~ 0.0021 in.)

[Limit]

Intake : 0.07 mm (0.0027 in.)

Exhaust : 0.09 mm (0.0035 in.)

Inspect valves.

(1)	Check that the valve is ground to the correct valve face angle.

(2)	Check the surface of the valve for wear. If the valve face is worn, replace the valve.

(3)

Check the valve head margin thickness.

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

Margin

[Standard]

Intake : 1.56 ~ 1.86 mm (0.06142 ~ 0.07323 in.)

Exhaust : 1.73 ~ 2.03 mm (0.06811 ~ 0.07992 in.)

(4)

Check the valve length.

Length

Intake : 105.27 mm (4.1445 in.)

Exhaust : 105.50 mm (4.1535 in.)

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

Inspect valve seats

Check the valve seat for evidence of overheating and improper contact with the valve face.

If the valve seat is worn, replace cylinder head.

Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.

Inspect valve springs.

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

(2)

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

Valve spring

[Standard]

Free height : 45.5 mm (1.7913 in.)

Out-of-square : 1.5°

MLA

Inspect MLAs.

Using a micrometer, measure the MLA outer diameter.

MLA O.D.

Intake/Exhaust :

34.964 ~ 34.980 mm (1.3765 ~ 1.3771 in.)

Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.

Tappet bore I.D.

Intake/Exhaust :

35.000 ~ 35.025 mm (1.3779 ~ 1.3789 in.)

Subtract MLA outer diameter measurement from tappet bore inner diameter measurement.

MLA to tappet bore clearance

[Standard]

Intake/Exhaust : 0.020 ~ 0.061 mm (0.0008 ~ 0.0024 in.)

[Limit]

Intake/Exhaust : 0.07 mm (0.0027 in.)

Reassembly

Thoroughly clean all parts to be assembled.

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

Replace oil seals with new ones.

Install the valves.

(1)

Using the SST (09222-2W100), push in a new oil seal.

Do not reuse old valve stem seals.

Incorrect installation of the seal could result in oil leakage past the valve guides.

(2)

Install the valve, valve spring and spring retainer.

Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer.

(3)	Using the SST (09222 - 3K000, 09222-3K100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.

(4)	Lightly tap the end of each valve stem two or three times with a soft hammer or the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.

Install the MLAs.

Check that the MLA rotates smoothly by hand.

MLA can be reinstalled in its original position.

However, the valve lash clearances must be rechecked and adjusted accordingly before the cylinder head is installed onto the cylinder block.

Refer to General information in EM section for Valve Clearance checking and adjustment procedure.

Install the LH/RH intake camshaft CVVT OCV (A).

Tightening torque :

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

•	Install OCV with gray colored connector into RH bank.

•	Install OCV with black colored connector into LH bank.

•	Do not reuse if OCV has been dropped.

•	Keep the OCV clean.

•	Do not hold the OCV sleeve during service.

•	When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.

Installation

•	Thoroughly clean all parts to be assembled.

•	Always use a new head and manifold gasket.

•	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 tomaintain clamping force.

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

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

[RH Cylinder Head]

Install the cylinder RH head.

a.	The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.

Apply TB 1217H sealant on cylinder block top face before assembling cylinder head gaskets.

The part must be assembled within 5 minutes after sealant was applied.

Refer to the following illustration to apply the sealant.

Bead width :

2.0 ~ 3.0 mm (0.078 ~ 0.118 in.)

Sealant locations :

1.0 ~ 1.5 mm (0.039 ~ 0.059 in.) from block surface

Recommended sealant : TB 1217H Liquid sealant

Apply TB 1217H sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.

The part must be assembled within 5 minutes after sealant was applied.

Be fully aware of the installation direction.

Install the RH cylinder head.

Remove the extruded sealant after assembling cylinder heads.

Install the RH cylinder head bolts.

(1)	Do not apply engine oil on the threads and under the heads of the cylinder head bolts.

(2)

Using SST (09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

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 tomaintain clamping force.

Tightening torque

Head bolt :

37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + (118 ~ 122°) + (88 ~ 92°)

Bolt (A) :

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

Install the rest of the parts in the reverse order of removal.

•	Refill engine oil.

•	Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.

•	Inspect for fuel leakage.

–	After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.

–	Repeat this operation two or three times, and then check for fuel leakage at any point on the fuel lines.

•	Refill radiator and reservoir tank with engine coolant.

•	Bleed air from the cooling system.

–	Start engine and let it run until it warms up.(Until the radiator fan operates 3 to 4 times.)

–	Turn off the engine and let it cool down. Check the level in the radiator, and add coolant if needed. This will allow trapped air to be released from the cooling system.

–	Put radiator cap on tightly, then run the engine again and check for leaks.

[LH Cylinder Head]

Install the cylinder LH head.

a.	The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.

Apply TB 1217H sealant on cylinder block top face before assembling cylinder head gaskets.

The part must be assembled within 5 minutes after sealant was applied.

Refer to the following illustration to apply the sealant.

Bead width :

2.0 ~ 3.0 mm (0.078 ~ 0.118 in.)

Sealant locations :

1.0 ~ 1.5 mm (0.039 ~ 0.059 in.) from block surface

Recommended sealant : TB 1217H (Hyundai Gray RTV) Liquid sealant

Apply TB 1217H sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.

The part must be assembled within 5 minutes after sealant was applied.

Be fully aware of the installation direction.

Install the LH cylinder head.

Remove the extruded sealant after assembling cylinder heads.

Install the LH cylinder head bolts.

(1)	Do not apply engine oil on the threads and under the heads of the cylinder head bolts.

(2)

Using SST (09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque

Head bolt :

37.3 ~ 41.2 N.m (3.8 ~ 4.2 kgf.m, 27.5 ~ 30.4 lb-ft) + (118 ~ 122°) + (88 ~ 92°)

Install the rest of the parts in the reverse order of removal.

•	Refill engine oil.

•	Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.

•	Inspect for fuel leakage.

–	After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.

–	Repeat this operation two or three times, and then check for fuel leakage at any point on the fuel lines.

•	Refill radiator and reservoir tank with engine coolant.

•	Bleed air from the cooling system.

–	Start engine and let it run until it warms up.(Until the radiator fan operates 3 to 4 times.))

–	Turn off the engine and let it cool down. Check the level in the radiator, and add coolant if needed. This will allow trapped air to be released from the cooling system.

–	Put radiator cap on tightly, then run the engine again and check for leaks.

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