Cylinder Head Assembly - 2.0L: Removal & Installation Kia Optima III

Removal

Timing chain cover removal is not required for this procedure.

Note. Mark all wiring and hoses to avoid misconnection. Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Remove the cylinder head cover. Refer to «TIMING SYSTEM»(ref-429532) .
2. Set No. 1 cylinder to TDC/compression. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover. Check that the TDC marks (A) of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°).
3. Mark the timing chains (A) corresponding to the timing marks of the CVVT sprockets.
4. Turn the crankshaft pulley 15° clockwise.
5. Remove the service hole bolt (A) of the timing chain cover. CAUTION: The bolt must not be reused once it has been disassembled.
6. Remove the intake and exhaust camshaft bearing caps.
7. Release the ratchet of the timing chain tensioner by pulling the link down using a thin rod.
8. After loosening the timing chain, remove the exhaust CVVT & camshaft assembly (A) and then the intake CVVT & camshaft assembly (B). CAUTION: When taking off the timing chain from the CVVT sprockets, hold the timing chain.
9. Tie down timing chain so that it doesn't move. CAUTION: Be careful not to drop anything inside timing chain cover.

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Hold the timing chain, and place the intake CVVT & camshaft assembly.
2. Place the exhaust CVVT & camshaft assembly after releasing the ratchet of the timing chain tensioner. NOTE: The timing marks of each CVVT sprocket should be matched with timing marks (painted link) of timing chain when installing the timing chain.
3. Install the camshaft bearing caps in their proper locations. Tightening order Group A --> Group B --> Group C Tightening torque Step 1 M6 : 5.9 N.m (0.6kgf.m, 4.3 lb-ft) M8 : 14.7 N.m (1.5kgf.m, 10.8 lb-ft) Step 2 M6 : 10.8 ~ 12.7 N.m (1.1 ~ 1.3kgf.m, 8.0 ~ 9.4 lb-ft) M8 : 27.5 ~ 31.4 N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1 lb-ft)
4. Install the service hole bolt (A). Tightening torque: 11.8 ~ 14.7 N.m (1.2 ~ 1.5kgf.m, 8.7 ~ 10.8 lb-ft)
5. Turn the crankshaft two turns in the operating direction (clockwise), and then check that the TDC marks (A) of the CVVT sprockets are in straight line on the cylinder head surface.
6. Install the cylinder head cover. Refer to cylinder head cover under «INSTALLATION»(ref-429532-S21404270692011101500000) .

Scheme 64

1. Disassemble the CVVT assembly (A) and camshaft (B).

Note. When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench.

Scheme 65

1. Reassemble the CVVT assembly (A) and camshaft (B). Tightening torque: 53.9 ~ 63.7 N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0 lb-ft) NOTE: When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench.

Scheme 66

Note. Mark all wiring and hoses to avoid misconnection.

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

1. Remove the engine cover.
2. Disconnect the battery negative terminal (A).
3. Remove the air duct (B).
4. Remove the air cleaner assembly and the intercooler inlet/outlet hoses. Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-429533-S22660766622011101500000) .
5. Remove the RH front wheel.
6. Remove the under covers.
7. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. Refer to «COOLING SYSTEM»(ref-429534) .
8. Disconnect the radiator upper hose (A) and lower hose (B).
9. Disconnect the wiring connectors and harness clamps, and remove the wiring protectors from the cylinder head, intake manifold and exhaust manifold. Disconnect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B). Disconnect the A/C compressor switch connector (A), the alternator connector (B), the OPS (Oil pressure switch) connector & injector extension connector (C), the knock sensor connector (D), the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (E), the ETC (Electronic throttle control) connector (F) and the vacuum pump connector (G). Disconnect the ignition coil connectors (A), the fuel pump connector (B). Disconnect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C). Disconnect the ECTS (Engine coolant temperature sensor) connector (A), the condenser connector (B), the CKPS (Crankshaft position sensor) connector (C), the exhaust CMPS (Camshaft position sensor) connector (D) and the electric wastegate actuator connector (E). Disconnect the intake CMPS (Camshaft position sensor) connector (A) and the PCSV (Purge control solenoid valve) connector (B).
10. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
11. Remove the vacuum pipe assembly (A).
12. Remove the high pressure pipe (A). Refer to «HIGH PRESSURE FUEL PUMP»(ref-429555-S42510784822011101500000) .
13. Remove the high pressure fuel pump (A) and the roller tappet (B). Refer to «HIGH PRESSURE FUEL PUMP»(ref-429555-S42510784822011101500000) .
14. Disconnect the heater hoses (A).
15. Disconnect the throttle body coolant hoses (A) and the oil cooler coolant hoses (B).
16. Remove the water temperature control assembly (A) with the water inlet pipe (B).
17. Remove the timing chain. Refer to «TIMING SYSTEM»(ref-429532) .
18. Remove the intake and exhaust manifold. Refer to «INTAKE AND EXHAUST SYSTEM»(/kia/optima/iii-2010-2013/remont/exhaust/#intake-system-and-exhaust-system-20l) .
19. Remove the high pressure fuel pump bracket (A).
20. Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B). NOTE: When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.
21. Remove the camshaft. Remove the front camshaft bearing cap (A) with the upper bearing (B). Remove the camshaft bearing cap (A) in the sequence shown. Remove the camshafts (A). Remove the exhaust camshaft lower bearing (A).
22. Remove the intake OCV (Oil control valve) (A) using a torx wrench and the OTS (Oil temperature sensor) (B).
23. Remove the exhaust OCV (Oil control valve) (A) using a torx wrench.
24. Remove the intake CMPS (Camshaft position sensor) (A).
25. Remove the exhaust CMPS (Camshaft position sensor) (A) after removing the engine hanger (B).
26. Remove the injector & rail module (A). Refer to «DELIVERY PIPE»(ref-429555-S14413366952011101500000) .
27. Remove the cylinder head. Using triple square wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order. Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench. CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. Remove the cylinder head gasket (B).

Installation

Note. Thoroughly clean all parts to be assembled. Always use a new 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.

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

1. Install the OCV (Oil control valve) filter. CAUTION: Keep the OCV filter clean.
2. Install the cylinder head gasket (A) on the cylinder block. NOTE: Be careful of the installation direction. Apply liquid gasket (Loctite 5900H or equivalent) on the edge of cylinder head gasket upside and downside. (At the position 'B') After applying sealant, assemble the cylinder head in five minutes.
3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
4. Install cylinder head bolts. Do not apply engine oil on the cylinder head bolts. Using the SST(09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown. Tightening torque: 32.4~36.3 Nm (3.3~3.7kgf.m, 23.9~26.8 lb-ft) + 90~95° + 90~95° CAUTION: Always use new cylinder head bolts.
5. Install the injector & rail module (A). Refer to «INSTALLATION»(ref-429555-S24103951812011101500000) . Pre-tighten the bolts and then tighten the bolts with the specified torque in the sequence shown. Tightening torque: 18.6~ 23.5 N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4 lb-ft)
6. Install the intake CMPS (Camshaft position sensor) (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)
7. Install the exhaust CMPS (Camshaft position sensor) (A) and the engine hanger (B). Tightening torque: Sensor bolt : 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft) Hanger bolt : 27.5 ~ 31.4 N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1 lb-ft)
8. Install the intake OCV (Oil control valve) (A) and the OTS (Oil temperature sensor) (B). Tightening torque: OCV bolt : 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft) OTS : 19.6 ~ 23.5 N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4 lb-ft)
9. Install the exhaust OCV (Oil control valve) (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft) CAUTION: Do not reuse the OCV when dropped. Keep the OCV filter clean. Do not hold the OCV sleeve (A) during servicing. When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
10. Install the camshafts. NOTE: Apply a light coat of engine oil on camshaft journals. Install the exhaust camshaft lower bearing (A). Install the camshafts (A). Install the exhaust camshaft upper bearing (A) to the front bearing cap. Install camshaft bearing caps (A) in their proper locations. Tightening order Group A --> Group B --> Group C. Tightening torque: Step 1 M6 : 5.9 N.m (0.6kgf.m, 4.3 lb-ft) M8 : 14.7 N.m (1.5kgf.m, 10.8 lb-ft) Step 2 M6 : 10.8 ~ 12.7 N.m (1.1 ~ 1.3kgf.m, 8.0 ~ 9.4 lb-ft) M8 : 27.5 ~ 31.4 N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1 lb-ft)
11. Install the intake CVVT assembly (A) and exhaust CVVT assembly (B). Tightening torque: 53.9 ~ 63.7 N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0 lb-ft) NOTE: When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.
12. Install the high pressure fuel pump bracket (A). Tightening torque: 18.6 ~ 23.5 N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4 lb-ft)
13. Install the intake and exhaust manifold. Refer to «INTAKE AND EXHAUST SYSTEM»(/kia/optima/iii-2010-2013/remont/exhaust/#intake-system-and-exhaust-system-20l) .
14. Install the timing chain. Refer to «INSTALLATION»(ref-429532-S21404270692011101500000) .
15. Check and adjust the valve clearance. Refer to «VALVE CLEARANCE INSPECTION AND ADJUSTMENT»(ref-429530-S15253485702011101500000) .
16. Install the water temperature control assembly (A) with the water inlet pipe (B). Tightening torque: Bolts : 14.7 ~ 19.6 N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5 lb-ft) Nut : 18.6 ~ 23.5 N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4 lb-ft) Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft) NOTE: Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened. Insert after wetting O-ring or inner surface of thermostat housing. Always use a new O-ring.
17. Install cylinder head cover. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover. After applying sealant (Loctite 5900H or equivalent), it should be assembled within 5 minutes. Bead width : 2.5 mm (0.10 in.) Install the cylinder head cover (A) by tightening the bolts as following method. Tightening torque: 1st step : 3.9 ~ 5.9 N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft) 2nd step : 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft) CAUTION: Do not reuse cylinder head cover gasket. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
18. Connect the throttle body coolant hoses (A) and the oil cooler coolant hoses (A).
19. Connect the heater hoses (A).
20. Install the high pressure fuel pump (A) and the roller tappet (B). Refer to «INSTALLATION»(ref-429555-S00600339522011101500000) . Tightening torque: 12.7 ~ 14.7 N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8 lb-ft) CAUTION: Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring. NOTE: Do not use already used bolt again. NOTE: When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque. CAUTION: Note that internal damage may occur when the component is dropped. In this case, use it after inspecting. NOTE: Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.
21. Install the high pressure pipe (A). Refer to «INSTALLATION»(ref-429555-S00600339522011101500000) . Tightening torque: Bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft) Nuts : 26.5 ~ 32.4 N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9 lb-ft) NOTE: Do not reuse the high pressure pipe.
22. Install the vacuum pipe assembly (A). Tightening torque: Bolt & nut : 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
23. Connect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
24. Connect the wiring connectors and harness clamps, and install the wiring protectors to the cylinder head, intake manifold and exhaust manifold. Connect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B). Connect the A/C compressor switch connector (A), the alternator connector (B), the OPS (Oil pressure switch) connector & injector extension connector (C), the knock sensor connector (D), the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (E), the ETC (Electronic throttle control) connector (F) and the vacuum pump connector (G). Connect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C). Connect the ignition coil connectors (A), the fuel pump connector (B). Connect the ECTS (Engine coolant temperature sensor) connector (A), the condenser connector (B), the CKPS (Crankshaft position sensor) connector (C), the exhaust CMPS (Camshaft position sensor) connector (D) and the electric wastegate actuator connector (E). Connect the intake CMPS (Camshaft position sensor) connector (A) and the PCSV (Purge control solenoid valve) connector (B).
25. Connect the radiator upper hose (A) and lower hose (B).
26. Install the under covers.
27. Remove the RH front wheel.
28. Install the intercooler inlet/outlet hoses and the air cleaner assembly. Refer to «INSTALLATION»(ref-429533-S11803263272011101500000) .
29. Install the air duct (B).
30. Connect the battery negative terminal (A). Tightening torque: 4.0 ~ 6.0 N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4 lb-ft)
31. Install the engine cover. Perform the following : Adjust shift cable. Refill engine with engine oil. Refill transaxle with fluid. Refill radiator and a reservoir tank with engine coolant. Clean battery posts and cable terminals and assemble. Inspect for fuel leakage. After assemble 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, then check for fuel leakage at any point in the fuel line. Bleed air from the cooling system. Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. Put radiator cap on tightly, then run the engine again and check for leaks.

See also:
• INTAKE AND EXHAUST SYSTEM