Engine Mechanical: Overhaul Kia Sedona II

DISASSEMBLY

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

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1. Remove MLAs (A).
2. Remove valves. Using SST (09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock. Remove the spring retainer. Remove the valve spring. Remove the valve. Using SST (09222-29000), remove the valve stem seal. NOTE: Do not reuse old valve stem seals.
3. Remove OCV (A).

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1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard: Less than 0.05 mm (0.002 in.) [Less than 0.02 mm (0.0008 in.)/150 x 150] Flatness of manifold gasket surface Standard: Less than 0.03 mm (0.001 in.)/110 x 110
2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

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1. Inspect valve stems and valve guides. 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.) 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.) 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.)
2. Inspect valves. 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. Margin [Standard] Intake: 1.56-1.86 mm (0.06142-0.07323 in.) Exhaust: 1.73-2.03 mm (0.06811-0.07992 in.) Check the valve length. Length Intake: 105.27 mm (4.1445 in.) Exhaust: 105.50 mm (4.1535 in.) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. 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.
4. Inspect valve springs. Using a steel square, measure the out-of-square of the valve spring. Using a vernier calipers, measure the free length of the valve spring. Valve spring [Standard] Free height: 43.86 mm (1.7267 in.) Out-of-square: 1.5°

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.

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1. Install valves. Using SST (09222-3C100), push in a new oil seal. NOTE: 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. NOTE: Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer. Using the SST (09222 - 3K000, 09222-3C300), 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.
2. Install MLAs. Check that the MLA rotates smoothly by hand. NOTE: MLA can be reinstalled in its original position.
3. Install OCV (A). Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: To install OCV with gray colored connector into RH bank. To install OCV with black colored connector into LH bank. CAUTION: Do not reuse the OCV when dropped. Keep the OCV assembly clean. Do not hold the OCV sleeve during servicing. When the OCV Is Installed on the engine, do not move the engine by holding the OCV yoke.

Note. Thoroughly clean all parts to assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

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1. Assemble piston and connecting rod. Use a hydraulic press for installation. The piston front mark and the connecting rod front mark must face the timing chain end of the engine.
2. Install piston rings. Install the oil ring spacer and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Position the piston rings so that the ring ends are (Scheme 129)
3. Install connecting rod bearings. Align the bearing claw with the groove of the connecting rod or connecting rod cap. Install the bearings (A) in the connecting rod and connecting rod cap (B).
4. Install main bearings. NOTE: Upper bearings have an oil groove and oil holes; Lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings (A).
5. Install thrust bearings. Install the 2 thrust bearings (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
6. Place crankshaft on the cylinder block.
7. Place main bearing caps on cylinder block.
8. Install main bearing cap bolts. Install and uniformly tighten the bearing cap bolts, in several passes, in the sequence shown in illustration. Tightening torque Main bearing cap bolt 49.00 N.m (5.0 kgf.m, 36.16 lb-ft) + 90° (1-8) 19.60 N.m (2.0 kgf.m, 14.46 lb-ft) + 120° (9-16) 29.40-31.36 N.m (3.0-3.2 kgf.m, 21.70-23.14 lb-ft) (17-22) NOTE: Always use new main bearing cap bolt. If any of the bearing cap bolts is broken or deformed, replace it. Use SST (09221-4A000), install main bearing cap bolts. Check that the crankshaft turns smoothly.
9. Check crankshaft end play. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-269574-S20596064862007110100000) )
10. Install piston and connecting rod assemblies. NOTE: Before installing the pistons, apply a coat of engine oil to the ring grooves and cylinder bores. Install the ring compressor, check that the bearing is securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer. Stop after the ring compressor pops free, and check the connecting rod-to-check journal alignment before pushing the piston into place. Apply engine oil to the bolt threads. Install the rod caps with bearings, and torque the bolts. Tightening torque 19.6 N.m (2.0 kgf.m, 14.46 lb-ft) + 90° Use SST (09221-4A000), install connecting rod bearing cap bolts. NOTE: Always use new connecting rod bearing cap bolt. Maintain downward force on the ring compressor to prevent the rings from expanding before entering the cylinder bore.
11. Check the connecting rod end play. (Refer to «CONNECTING ROD AND CRANKSHAFT»(ref-269574-S20596064862007110100000) )
12. Install oil drain cover. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: Ensure the sealing face is clean before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant Before assembling oil drain cover, the liquid sealant TB1217H should be applied oil drain cover. The part must be assembled within 5 minutes after sealant was applied. Apply sealant to the inner threads of the bolt holes.
13. Install rear oil seal case. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.67 lb-ft) NOTE: Make clean the sealing face before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant Before assembling rear oil seal case, the liquid sealant TB1217H should be applied rear oil seal case. The part must be assembled within 5 minutes after sealant was applied. Apply sealant to the inner threads of the bolt holes.
14. Using SST (09231-3C200, 09231-H1100), install rear oil seal.
15. Install baffle plate. Install and uniformly tighten the baffle plate bolts, in several passes, in the sequence shown in illustration. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
16. Install upper oil pan. Using a gasket scraper, remove all the old packing material from the gasket surfaces. Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan. The part must be assembled within 5 minutes after the sealant was applied. Bead width: 2.5 mm (0.1 in.) NOTE: Ensure the sealing face is clean before assembling two parts. Remove harmful foreign matters on the sealing face before applying sealant When applying sealant gasket, sealant must not be protruded into the inside of oil pan. To prevent leakage of oil, apply sealant gasket of the inner threads of the bolt holes. Install upper oil pan. Uniformly tighten the bolts in several passes. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
17. Install knock sensor. Tightening torque 15.68-23.52 N.m (1.6-2.4 kgf.m, 11.57-17.36 lb-ft)
18. Install drive plate. Tightening torque 71.54-75.46 N.m (7.3-7.7 kgf.m, 52.80-55.69 lb-ft)

WATER TEMPERATURE CONTROL ASSEMBLY

Note. Make clean the contact face before assembly.

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1. Install water temperature control assembly (B) and new gasket (A). Tightening torque 18.62-23.52 N.m (1.9-2.4 kgf.m, 13.74-17.36 lb-ft) NOTE: Use new O-rings (C) when reassembling.
2. Connect water hoses to the water temperature control assembly.
3. Install wiring protector.
4. Connect ECT connector.
5. Connect radiator upper and lower hose (A).
6. Install air cleaner assembly.
7. Fill with engine coolant.
8. Start engine and check for leaks.
9. Recheck engine coolant level.

OIL FILTER ASSEMBLY

1. Install oil filter body (A) and new O-rings. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft) NOTE: All rubber gasket must be no damaged by assembling parts. Be careful of the knock sensor connector. Always use a new O-ring
2. Install oil filter body cover (B) and new gasket on the oil filter body. Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
3. Connect water vent hose (A) Tightening torque 9.80-11.76 N.m (1.0-1.2 kgf.m, 7.23-8.68 lb-ft)
4. Install water temperature control assembly. (Refer to «WATER TEMPERATURE CONTROL ASSEMBLY»(ref-269574-S08855888072007110100000) )
5. Connect water hoses on the ETC.
6. Connect oil pressure switch connector.
7. Install intake manifold and surge tank. (Refer to «INTAKE MANIFOLD»(ref-269574-S00420520242007110100000) )
8. Fill with engine coolant.
9. Start engine and check for leaks.
10. Recheck engine coolant level.

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