Kia Rio: 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 (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.

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)

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

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

Remove the spring retainer.

Remove the valve spring.

Remove the valve.

Using the pliers, remove the valve stem seal.

Do not reuse old valve stem seals.

Flatness of cylinder head gasket surface

Standard : Less than 0.05 mm (0.0020 in)

Less than 0.02 mm (0.0008 in) / 100 x 100

Flatness of manifold gasket surface

Standard : Less than 0.1 mm (0.0039 in)

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

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

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

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

Check that the surface of the 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 valve length.

Check the surface of the 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 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.

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

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

Thoroughly clean all parts to be assembled.

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

Using the SST (09222-03100), push in a new valve stem seal.

• Do not reuse old valve stem seals. • Incorrect installation of the seal could result in oil leakage past the valve guides.

Install the valve, valve spring and spring retainer.

Place valve springs so that the cone shape side is upward retainer side.

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.

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

Until installing HLA shall be held upright so that engine oil in HLA should not spill and assured that dust does not adhere to HLA.

HLA shall be inserted tenderly to the cylinder head not to spill engine oil from HLA. In case of spilling, air vent shall be done in accordance with the air bent procedure.

Stroke HLA in engine oil 4-5 times by pushing its cap while pushing the ball down slightly by hard steel wire. (Take care not to severely push hard steel wire down since ball is several grams.)

After installed on engine, lash adjuster might give out unusual noise. If air is mingled then apply slow racing (Approx. one minute for 1 racing) from idle to 3000rpm and is removed from adjuster.

Thoroughly clean all parts to be assembled.

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.

The sealant locations on cylinder head gasket, cylinder block and timing chain lower case must be free of engine oil and etc.

Apply sealant TB1217 or LT5900 on the cylinder block top surface (Refer to below illustration) before assembling the cylinder head gasket.

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

Be careful of the installation direction.

Apply sealant TB1217 or LT5900 on the cylinder head gasket top surface (Refer to below illustration) after assembling the cylinder head gasket.

Remove the extruded sealant after assembling the cylinder head assembly.

Place the cylinder head assembly (A) quietly in order not to damage the gasket with the bottom part of the end.

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 to maintain clamping force.