Repair Procedures: Adjustment

NOTE: Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature: 20°C) and cylinder head is installed on the cylinder block.

Remove the cylinder head cover.
Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
  
  Fig 1: Identifying Crankshaft Pulley And Timing Mark
  Courtesy of KIA MOTORS AMERICA, INC.
2. Check that the marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°).
  
  Fig 2: Identifying Marks Of Intake And Exhaust CVVT Sprockets
  Courtesy of KIA MOTORS AMERICA, INC.
Inspect the valve clearance.
1. Check only the intake valves of the 1st and 2nd cylinders and exhaust valves of the 1st and 3rd cylinders for their clearance.
  1. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.
    
    Fig 3: Identifying Clearance Between Tappet And Base Circle Of Camshaft
    Courtesy of KIA MOTORS AMERICA, INC.
  2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required tappet for adjusting.
  Valve clearance specification (Engine coolant temperature: 20°C [68°F])
  
  Limit
  
  Intake: 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)
  
  Exhaust: 0.22 ~ 0.28mm (0.0087 ~ 0.0110in.)
2. Turn the crankshaft pulley one revolution (clockwise 360°) and align its groove with timing mark of the timing chain cover.
3. Check the intake valves of the 3rd and 4th cylinders and exhaust valves of the 2nd and 4th cylinders for their clearance.
  
  Fig 4: Identifying Intake And Exhaust Valves Clearance
  Courtesy of KIA MOTORS AMERICA, INC.
Adjust the intake and exhaust valve clearance.
1. Set the No. 1 cylinder to the TDC/compression position.
2. Remove the timing chain. (Refer to TIMING CHAIN .
  NOTE: Put paint marks on the timing chain links (2 places) that meet with the timing marks of the intake and exhaust CVVT sprockets.
  
  Fig 5: Identifying Timing Chain Link
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 6: Identifying Timing Chain Link
  Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the camshaft bearing caps (A) with the order below.
  
  Fig 7: Identifying Camshaft Bearing Caps
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the intake camshaft assembly.
5. Remove the exhaust camshaft assembly.
6. Measure the thickness of the removed tappet using a micrometer.
  
  Fig 8: Measuring Thickness Of Removed Tappet Using Micrometer
  Courtesy of KIA MOTORS AMERICA, INC.
7. Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.
  Valve clearance (Engine coolant temperature: 20°C)
  
  T: Thickness of removed tappet
  
  A: Measured valve clearance
  
  N: Thickness of new tappet
  
  Intake: N = T + [A - 0.20mm (0.0079in.)]
  
  Exhaust: N = T + [A - 0.25mm (0.0098in.)]
8. Select a new tappet with a thickness as close as possible to the calculated value.
  NOTE: Shims are available in 41 size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.690mm (0.1417in.)
9. Place a new tappet on the cylinder head.
10. Install the exhaust camshaft assembly.
11. Install the intake camshaft assembly.
12. Install the camshaft bearing caps with the order below.
  Tightening torque:
  
  1st step
  
  M6 bolt:
  
  5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
  
  M8 bolt:
  
  9.8 N.m (1.0 kgf.m, 7.2 lb-ft)
  
  2nd step
  
  M6 bolts:
  
  11.8 ~ 13.7 N.m (1.2 ~ 1.4 kgf.m, 8.7 ~ 10.1 lb-ft)
  
  M8 bolts:
  
  18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)
  
  Fig 9: Identifying Camshaft Bearing Caps
  Courtesy of KIA MOTORS AMERICA, INC.
13. Install the timing chain. (Refer to TIMING CHAIN .
14. Turn the crankshaft two turns in the operating direction (clockwise) and check that the marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface.
  
  Fig 10: Identifying Marks Of Intake And Exhaust CVVT Sprockets
  Courtesy of KIA MOTORS AMERICA, INC.
15. Recheck the valve clearance.
  Valve clearance (Engine coolant temperature: 20°C)
  
  [Specification]
  
  Intake: 0.17 ~ 0.23mm (0.0067 ~ 0.0091in.)
  
  Exhaust: 0.22 ~ 0.28mm (0.0087 ~ 0.0110in.)