Kia Rio YB Quiz
Engine Mechanical System

Cylinder head cover

In this manual: Engine Mechanical System
General Information — 8Maintenance — 31Engine Mechanical System — 44Engine Electrical System — 14Emission Control System — 9Engine Control System/Fuel System — 30Clutch System — 10Manual Transmission — 10Automatic Transmission — 23Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 14Brake System — 22Body (Interior and Exterior) — 115Body Electrical System — 84Heating, Ventilation, and Air Conditioning — 28
35steps
~225min
5/5difficulty
3special tools
0102030405011.89N·mlb·ft
Tightening torque found on this page
Done 0 of 35

Components and Component Location

Components

1. Cylinder Head Assembly
2. Cylinder Head Gasket
3. Rocker Arm
4. HLA (Hydraulic Lash Adjuster)
5. Retainer Lock		 6. Retainer
7. Valve Spring
8. Valve Stem Seal
9. Valve
10. Cylinder Head Bolt

Repair Procedures

Removal

Engine removal is not necessary for this procedure.

  1. Remove the engine cover.

    (See Engine and Transaxle Assembly - Engine Cover)

  2. Remove the battery.

    (Refer to Engine Electrical System - Battery)

  3. Remove the engine room cover.

    (See Engine and Transaxle Assembly - Under Hood)

  4. Drain the engine coolant.

    (See Cooling System - Coolant).

  5. Remove the air cleaner assembly.

    (See Intake and Exhaust System - Air Cleaner)

  6. Disconnect the upper radiator hose (A).

  7. Disconnect the brake booster vacuum hose (A) and the heater hoses (B).

  8. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).

  9. Remove the water temperature control assembly.

    (See Cooling System - "Water Temperature Control Assembly")

  10. Remove the cylinder head cover.

    (Refer to Cylinder Head Assembly - "Cylinder Head Cover")

  11. Remove the intake manifold.

    (See Intake and Exhaust System - Intake Manifold)

  12. Remove the delivery pipe assembly.

    (See Engine Control/Fuel System - "Delivery Pipe")

  13. Remove the exhaust manifold.

    (See Intake and Exhaust System - Exhaust Manifold)

  14. Remove the timing chain.

    (See Timing System - Timing Chain)

  15. Remove the variator and camshaft.

    (Refer to Cylinder Head Assembly - "CVVT and Camshaft")

  16. Remove the vacuum hose (A).

    Tightening Torque: 9.8–11.8 N·m

  17. Remove the solenoid valve bracket (A).

    Tightening torque: 18.6 – 24 N·m

  18. Remove the intake camshaft position sensor (CMPS).

    (See Engine Control System/Fuel System - Camshaft Position Sensor)

  19. Remove the exhaust CVVT oil control valve (OCV).

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

  21. Lift the cylinder head (A) off the dowels on the cylinder block and place the cylinder head on wooden blocks on the workbench.

  22. Remove the cylinder head gasket (A).

Disassembly

  1. Remove the rocker arm and hydraulic lash adjuster assembly (A).

  2. Remove the valves.

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

    2. Remove the spring retainer.

    3. Remove the valve spring.

    4. Remove the valve.

    5. Using pliers, remove the valve stem seal.

Inspection

Cylinder head cover

  1. Inspect for flatness.

    Using a precision straightedge and feeler gauge, measure the cylinder head and manifold contact surface for warpage.

    If the flatness exceeds the maximum, replace the cylinder head.

    Cylinder head gasket surface flatness

    Standard: Less than 0.05 mm (0.0020 in.)

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

    Manifold gasket surface flatness

    Standard: Less than 0.1 mm (0.0039 in.)

  2. Inspect for cracks.

    Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If any cracks are found, replace the cylinder head.

Valve and Valve Spring

  1. Inspect the valve stems and valve guides.

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

      Valve guide inside diameter

      Intake/Exhaust:

      5.500–5.512 mm (0.2165–0.2170 in.)

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

      Valve stem outside diameter

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

      Exhaust: 5.448–5.460 mm (0.2144–0.2149 in.)

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

      Valve stem-to-guide clearance

      Intake: 0.020–0.047 mm (0.00078–0.00185 in.)

      Exhaust: 0.040–0.064 mm (0.00157–0.00251 in.)

  2. Inspect the valves.

    1. Make sure the valve face is ground to the correct valve face angle.

      Valve face angle: Intake/Exhaust: 45.25° - 45.75°

    2. Inspect the valve face for wear. If the valve face is worn, replace the valve.

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

      Limit

      Intake: 1.35–1.65 mm (0.0531–0.0650 in.)

      Exhaust: 1.60–1.90 mm (0.0630–0.0748 in.)

    4. Check the valve length.

      Length Intake: 100.94 mm (3.9740 in.) Exhaust: 101.09 mm (3.9799 in.)

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

  3. Inspect the valve seats.

    1. Inspect the valve seat for signs of overheating and improper contact with the valve face.

      If the valve seat is worn, replace the cylinder head.

    2. Before resurfacing the seat, check the valve guide for wear. If the valve guide is worn, replace the cylinder head.

    3. Recondition the valve seat using a seat grinder or cutter. The valve seat contact width must meet the specifications and be centered on the valve face.

      Valve seat contact width:

      Intake: 0.85–1.15 mm (0.0334–0.0452 in.)

      Exhaust: 1.35–1.65 mm (0.0531–0.0649 in.)

      Valve seat angle:

      Intake/Exhaust: 44.75° - 45.10°

  4. Inspect the valve springs.

    1. Using a steel square, measure the valve spring squareness.

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

      Valve Spring

      Free height: 47.9 mm (1.8858 in.)

      Runout: 1.5° (MAX.)

HLA (Hydraulic Lash Adjuster)

When the HLA is filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.

Symptom Possible Cause Action
1. Temporary noise when starting a cold engine Normal This noise will disappear after the engine oil reaches normal pressure.
2. Continuous noise when starting the engine after the vehicle has been parked for more than 48 hours. Oil leaks from the HLA high-pressure chamber, allowing air to enter. The noise will disappear within 15 minutes when the engine is run at 2000–3000 rpm. If it does not disappear, see step 7 below.
3. Continuous noise when starting the engine for the first time after cylinder head reconditioning. Insufficient oil in the cylinder head oil passage.
4. Continuous noise when starting the engine after excessive cranking of the engine with the starter or belt. Oil leaks from the HLA high-pressure chamber, allowing air to enter. Insufficient oil in the HLA.
5. Continuous noise when running the engine after replacing the HLA. Do not run the engine above 3000 rpm, as this may damage the HLA.
6. Continuous noise at idle after high engine speed operation. Engine oil level is too high or too low. Check the oil level. Drain or add oil as necessary.
Excessive air in the oil at high engine speed. Check the oil supply system.
Deteriorated oil. Check the oil quality. If the oil has deteriorated, replace it with oil of the specified type.
7. Noise continues for more than 15 minutes. Low oil pressure. Check the oil pressure and the oil supply system to each engine component.
Faulty HLA. Remove the cylinder head cover and press the HLA down by hand. If it moves, replace the HLA.
Be careful of hot HLAs.

Installation

  1. Install the valves.

    1. Using SST (09222-03100), install a new valve stem seal.

    2. Install the valve, valve spring and spring seat.

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

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

  2. Install the rocker arm and hydraulic lash adjuster assembly (A).

    1. Before installing the HLA, keep it upright so that engine oil does not spill from the HLA and dust does not adhere to it.

    2. Insert the HLA carefully into the cylinder head so that engine oil does not spill from it. If oil spills, bleed air using the air bleeding procedure.

Installation

  1. Install the cylinder head gasket.

    1. The sealant application areas on the cylinder head gasket, cylinder block and timing chain lower cover must be cleaned of engine oil and similar contaminants.

    2. Apply TB1217 or LT5900 sealant to the upper surface of the cylinder block before installing the cylinder head gasket (see illustration below).

      Bead width: 2.0–3.0 mm (0.0787–0.1181 in.)

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

    4. Apply TB1217 or LT5900 sealant to the upper surface of the cylinder head gasket (see illustration below) after installing the cylinder head gasket.

      Bead width: 2.0–3.0 mm (0.0787–0.1181 in.)

    5. Remove any squeezed-out sealant after assembling the cylinder head.

  2. Install the cylinder head assembly.

    1. Install the cylinder head assembly (A) carefully so as not to damage the gasket with the lower end.

    2. Tighten the cylinder head bolts and washers in several steps in the order shown.

      Tightening torque:

      12,7–16.7 N·m + 90 - 95° + 120 - 125°

  3. Install the remaining parts in the reverse order of removal.

Test yourself

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