Kia 221103CAB0A Cylinder Head Sub Assembly

Before removing the cylinder head, it is necessary to depressurize the fuel system, and separate the cable for the negative terminal on the battery. Pull the radiator and evaporator and the water pump and drain The inter cooler and expel the exhaust manifold/heads. Subsequently, take out the timing belt or timing chain from the camshaft sprockets and extract the camshafts. Remove all the sensors and hoses you can, and finally, undo the cylinder head bolts with 1/4-turn intervals to the point where they can be easily removed by hand along with their hardened washers; do not remove the M6 bolt at the front of the cylinder heads on the 2006 and later models. Remove the cylinder head from the engine block, it's also recommend to use wooden block with hammer and should apply extra caution not to bend the head while lifting from the block as this might cause damages to the gasket surface. Lastly, for inspection, with the help of a precision straight edge run it across the gasket surfaces of each head and measure the clearance to make sure it falls within the standard limits; the areas should also be checked for cracks and coolant leakage. Before tightening, make sure the contact surfaces of the cylinder heads and block, are free of the old gasket material by scraping with a gasket scraper soaked in brake cleaner. Admiral the corner edges as well for indentations, peening, nicks, and /or scratches; whether minor or significant, the file/machining should adequate. Using a tap run the threads in the cylinder head bolt holes and blow clean with compressed air. Remove small dirt or whatsoever from the bolts, and if any of the bolts is found to be stretched or rusted must be replaced. Simply line up the new gaskets to the dowel pins in the block, aligning them correctly, then apply RTV seal as recommended. Place the head gently onto the block in a manner that does not compromise the gasket; you should apply clean engine oil on the thread of the bolts to be tightened. Loosen the bolts as stated then in the recommended sequence and finally tighten the bolts to the torque that has been recommended excluding the small one at the front of the cylinder heads. To recap, undo the removal operation, fill the cooling system, change the engine oil and filter as well as start the engine and ensure, any leaks are rectified.

To remove the cylinder head, first relieve the fuel system pressure and disconnect the cable from the negative terminal of the battery. Drain the cooling system, including the engine block, and then remove the upper and lower intake manifolds, followed by the exhaust manifold(s). Disconnect the timing belt or timing chain from the camshaft sprockets and remove the camshafts. Disconnect any remaining sensors or hoses, then loosen the cylinder head bolts in 1/4-turn increments until they can be removed by hand, along with their hardened washers, and lift the cylinder head off the engine block, using a wood block and hammer if necessary, while avoiding prying between the head and block to prevent gasket surface damage. For inspection, use a precision straightedge to check the gasket surfaces of each head, inserting a feeler gauge of the maximum specified size, and examine the intake and exhaust manifold surfaces as well as the block surface for cracks and coolant leakage. During installation, ensure the mating surfaces of the cylinder heads and block are perfectly clean, using a gasket scraper and brake cleaner to remove all traces of carbon and old gasket material, while stuffing the cylinders with clean shop rags to keep out debris. Check the block and head mating surfaces for damage, using a file for slight damage and considering machining for excessive damage. Chase the threads in the cylinder head bolt holes with a tap and clean them with compressed air, then restore the threads on each bolt using a die. Position the new gaskets over the dowel pins in the block, ensuring they are right side up and aligned correctly, applying RTV sealant as specified. Carefully set the head on the block without disturbing the gasket, apply clean engine oil to the bolt threads, and install the bolts, tightening them finger tight before following the recommended sequence for final torque. Install and tighten the small bolt at the front of the cylinder heads, then complete the installation in reverse order of removal. Finally, refill the cooling system, change the oil and filter, run the engine, and check for leaks.

Before the removal, Lower the fuel system pressure and detach the ground cable from the negative terminal of the battery and drain the engine coolant. Take off the intake manifold, but this is optional and can stay in place, and unscrew the coolant hoses on the cylinder head. Subsequently, take out the timing chain and cam sprockets, securely jack up the car and support it further with stands, and disconnect exhaust manifold. Bolt and socket the electrical connectors from the cylinder head and take out the Oil Control Valve, and both Camshaft Position sensors. In the case of GDI models, the fuel injector and rail assembly should be pulled out. It will be useful to subsequently turn the cylinder head bolts in a manner that is opposite to the initial sequence that you applied to tighten it, but in intervals of no more than 1/4 turn until you are ready to fully unscrew all the bolts. Supported by the cradle, take the cylinder head off the engine block with difficulty if necessary, and clean the head as well as other external parts that can be easily removed together with it. Every head should be brought up and examined for specific gap areas on the gasket surfaces with the help of the precision straightedge and the feeler gauge, which should be inserted in relevant gaps, and all the areas of heads should be searched for crack lines and signs of coolant leakage. First, make certain that there is no carbon or old gasket left on the mating surfaces of the cylinder head and block, you may use a gasket scraper and brake system cleaner. Place clean shop rags inside the cylinders to prevent the entry of such debris and then, remove the material within them with a vacuum cleaner. The two mating surfaces on block and cylinder head should also be smooth with no nicks and scratches, if slight, they should be filed while if they are badly damaged they should be machined. With the tap, chase the threads of the cylinder head bolt holes and blow off the debris using compressed air. It is recommended that you clean the threads on each bolt with a wire brush and have the ones that are damaged replaced. Reinstall the components, which have been removed from the cylinder head, spread the liquid gasket on front corner edges of the gasket, and install the new gasket to fit the dowel pins in the block while making sure the identifier mark is up. Place the cylinder head gently onto the block such that the gasket remains intact, what must happen within five minutes of the usage of the liquid gasket. To the threads and under the bolt heads apply clean engine oil: before installing the cylinder head bolts, new head bolts and washers must be installed and turned only with fingers. As it is described, follow the sequence when tightening the bolts up to the prescribed torque, also an additional 90-degrees are applied, in the further stages of sequence. If any new parts are fitted on the car ensure that the next torque settings do follow the correct sequence. The rest of the installation is a reversal of the removal process to guarantee proper positioning of the timing chain. Last but not the least, replace the engine oil and filter, Fill up the cooling system, Start the engine and look for any sign of leakage.