FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Kia >> 2007 >> Spectra L4-2.0L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Replacement >> Installation

Installation






INSTALLATION

NOTE:
- Thoroughly clean all parts to be assembled.
- Always use a new cylinder head and manifold gasket.
- The cylinder head gasket is a metal gasket. Take care not to bend it.
- Rotate the crankshaft, set the No. 1 piston at TDC.

1. Install the cylinder head gasket(A) on the cylinder block.

NOTE:
Be careful of the installation direction.




2. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged, fluid leakage could occur.
3. Install the cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque :
M10: 22.6 - 26.5N-m (2.3 - 2.7kg-m, 16.6 - 19.5lb-ft)+60°~65° + 60°~65°
M12: 27.5 - 31.4N-m (2.8 - 3.2kg-m, 20.3 - 23.1lb-ft)+60°~65° + 60°~65°





4. Install the OCV(Oil Control Valve) filter(A).

Tightening torque :
40.2 - 50.0N-m (4.1 - 5.1kg-m, 29.7 - 36.9lb-ft)






NOTE:
- Always use a new OCV(Oil Control Valve) filter gasket.
- Keep the OCV filter clean.

5. Install the OCV(Oil Control Valve)(A).

Tightening torque :
9.8 - 11.8N-m (1.0 - 1.2kg-m, 7.2 - 8.7lb-ft)






CAUTION:
- Do not reuse the OCV(Oil Control Valve) when dropped.
- Keep the OCV clean.
- Do not hold the OCV(Oil Control Valve) sleeve during servicing.
- When the OCV is installed on the engine, be careful not to rotate the engine while holding the yoke.

6. Install the camshafts.
(1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.




(2) Install the camshaft(A) and bearing caps(B).

Tightening torque :
13.7 - 14.7N-m (1.4 - 1.5kg-m, 10.1 - 10.8lb-ft)





(3) Install the timing chain auto tensioner(A).

Tightening torque :
7.8 - 9.8N-m (0.8 - 1.0kg-m, 5.8 - 7.2lb-ft)





(4) Remove the auto tensioner stopper pin(B).
7. Check and adjust valve clearance.
8. Using the SST (09221 - 21000), install the camshaft bearing oil seal.




9. Install the camshaft sprocket.
10. Install the cylinder head cover.
(1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B).





NOTE:
- Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove.
- When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap.

(2) Apply liquid gasket to the head cover gasket at the corners of the recess.





NOTE:
- Use liquid gasket, loctite No. 5999.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- After assembly, wait at least 30 minutes before filling the engine with oil.

(3) Install the cylinder head cover(A) with the 12 bolts(B). Uniformly tighten the bolts in several passes.

Tightening torque :
7.8 - 9.8N-m (0.8 - 1.0kg-m, 5.8 - 7.2lb-ft)





11. Install the PCV(Positive Crankcase Ventilation) hose.
12. Install the timing belt.
13. Install the intake manifold.
14. Install the exhaust manifold.
15. Install the spark plug cables.




16. Install the power steering pump bracket(A) and bolts(B, C).

Tightening torque :
Bolt (B) : 34.3 - 49.0N-m (3.5 - 5.0kg-m, 25.3 - 36.2lb-ft)
Bolt (C) : 11.8 - 14.7N-m (1.2 - 1.5kg-m, 8.7 - 10.8lb -ft)





17. Install the power steering pump.
18. Install the accelerator cable.
19. Install the brake booster hose(C).
20. Connect the hose(B) of the PCSV (Purge Control Solenoid Valve) side.
21. Connect the fuel inlet hose(A) of the delivery pipe side.




22. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
(1) Connect the PCSV(Purge Control Solenoid Valve) connector(A).




(2) Connect the front heated oxygen sensor connector (A).
(3) Connect the CKP(Crankshaft Position Sensor) connector(B).
(4) Connect the oil pressure switch connector(C).




(5) Connect the air conditioner compressor switch connector(F).
(6) Connect the ground cables(D, E) to intake manifold and vehicle's body.
(7) Connect the knock sensor connector(C).
(8) Connect the fuel injector connectors(B).
(9) Connect the CMP(Camshaft position sensor) connector(A).




(10) Connect the ISA(Idle Speed Actuator) connector(B).
(11) Connect the TPS (Throttle Position Sensor) connector (A).




(12) Connect the ignition coil connector(D).
(13) Connect the ECT (Engine Coolant Temperature) connector(C).
(14) Connect the oil temperature sensor connector(B).
(15) Connect the OCV(Oil Control Valve) connector(A).




23. Install the heater hose(A).




24. Install the upper radiator hose(A) and lower radiator hose(B).




25. Install the intake air hose and air cleaner assembly.
(1) Install the air cleaner lower cover(A) and bolts(B).

Tightening torque :
7.8 - 9.8N-m (0.8 - 1.0kg-m, 5.8 - 7.2lb-ft)





(2) Install the air cleaner element.
(3) Install the intake air hose(D) and air cleaner upper cover(C).
(4) Install the breather hose(B) to intake air hose(D).
(5) Connect the AFS(Air Flow Sensor) connector(A).




26. Install the engine cover.

Tightening torque :
3.9 - 5.9N-m (0.4 - 0.6kg-m, 2.9 - 4.3lb-ft)





27. Install the heat shield(B) and connect the battery terminals(A) to the battery.




28. Fill with engine coolant.
29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.
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