Kia Soul: Cylinder Head Installation

Second generation PS (2014-2019) / Kia Soul 2014-2019 PS Service Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head Installation

•	Thoroughly clean all parts to be assembled.

•	Always use a new cylinder head and manifold gasket.

•	Always use new cylinder head bolts. Cylinder head bolts are toque-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.

Install the cylinder head assembly.

(1)	Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.

(2)

Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.

Refer to the illustration for applying sealant.

Width : 2.0 ~ 3.0mm(0.0787~0.1181in.)

Position : 1.0 ~ 1.5mm(0.0394~0.0591in.)

Specification : TB 1217H or LOCTITE 5900H

(3)	After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes.

2.	Place the cylinder head carefully not to damage the gasket.

Install the cylinder head bolts with washers.

(1)

Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.

Tightening torque :

29.4Nm (3.0kgf.m, 21.7lb-ft) + 90° + 90°

Always use new cylinder head bolts. Cylinder head bolts are toque-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.

4.	Install the oil control valve(OCV). (Refer to Engine Control / Fuel System - "CVVT Oil Control Valve (OCV)")

5.	Install the heater pipe. (Refer to Cooling System - "Water Pipe")

6.	Install the weter control assembly, and bypass hose. (Refer to Cooling System - "Water Control Assembly")

7.	Install the delivery pipe assembly. (Refer to Engine Control / Fuel System - "Delivery Pipe")

8.	Install the intake manifold. (Refer to Intake And Exhaust System - "Intake Manifold")

9.	Install the exhaust manifold. (Refer to Intake And Exhaust System - "Exhaust Manifold")

10.	Install the cam shaft. (Refer to Cylinder Head Assembly - "CVVT & Camshaft")

11.	Install the timing chain. (Refer to Timing System - "Timing Chain")

12.	Install the timing chain cover. (Refer to Timing System - "Timing Chain Cover)

13.	Install the OCV(Oil Control Valve) adaptor. (Refer to Engine Control / Fuel System - "CVVT Oil Control Valve")

14.

Install the cylinder head cover.

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

Do not reuse the disassembled gasket.

15.	Install the exhaust OCV (Oil control valve). (Refer to Engine Control / Fuel System - "CVVT Oil Control Valve")

16.	Install the ignition coil. (Refer to Engine Electrical System - "Igniton Coil")

17.	Install the high pressure fuel pump and the roller tappet. (Refer to Engine Control / Fuel System - "High Pressure Fuel Pump")

18.

Install the vacuum pipe assembly (A).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

19.	Connect the brake booster vacuum hose (A) and heater hose (B).

20.	Connect the The ETC (Electronic throttle control) connector and the MAPS (Manifold absolute pressure sensor). (Refer to Engine Control / Fuel System - "Engine Control System components)

21.	Connect the ECTS (Engine coolant temperature sensor) connector. (Refer to Engine Control / Fuel System - "Engine Control System")

22.	The A/C compressor switch connector, the alternator connector and the cable from the alternator “B” terminal. (Refer to Engine Electrical System - "Alternator)

23.	Connect the aircon compressor connector. (Refer to Heating, Ventilation, Air Conditioning - "Compressor")

24.	Install the radoator upper hose and lower hose. (Refer to Cooling System - "Radiator Hose")

25.	Install the engine room under cover.

26.	Install the ECM and then connect the ECM connector. (Refer to Engine Electrical System - "Battery")

27.	Install the battery.

28.	Instal the air duct and air clean assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

29.	Install the battery assembly.

30.	Install the engine cover.

Perform the following :

•	Refill engine with engine oil.

•	Refill a radiator and a reservoir tank with engine coolant.

•	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.

Cylinder Head Reassembly

• Thoroughly clean all parts to be assembled. • ...

Engine And Transmission Assembly

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