Kia Stinger: Cylinder Head Assembly / CVVT & Camshaft
Description and operation
Electric E-CVVT system is electric continuous variable valve timing system. It
is located on the intake camshaft of the engine and uses motor rotation to control
the rotation angle of camshaft relative to the rotation of crankshaft regardless
of engine pressure. E-CVVT controls the DC motor current (duty signal) to more closely
control the system compared to the previous pressure type, to increase reaction
speed of cam, to improve startability, and to reduce the emission of exhaust gas.
Also, operation range of intake valve (valve opening angle) is expanded. So, the
output and fuel efficiency are improved.
Repair procedures
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Use fender covers to avoid damaging painted surfaces.
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| • |
To avoid damage, unplug the wiring connectors carefully while
holding the connector portion.
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| • |
Mark all wiring and hoses to avoid misconnection.
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| • |
Turn the crankshaft pulley so that the No. 1 piston is at top
dead center.
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| 1. |
Remove the timing chain
(Refer to Timing System - "Timing chain")
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| 2. |
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
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| 3. |
Remove the fuel pump bracket (A).
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| 4. |
Remove it by breaking the center of E-CVVT motor plug (A).
| •
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Remove after 30 minutes of switching "OFF" the ignition
to drain out the oil inside the E-CVVT motor plug.
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| •
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Do not tilt the front of engine (timing chain cover side)
downward as residual oil may flow out during E-CVVT motor
plug removal.
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| •
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If oil flows out during E-CVVT motor plug removal, wipe
off immediately and block the motor shaft inlet with a clean
towel.
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| 5. |
Disconnect the intake E-CVVT assembly (A) and exhaust CVVT assembly (B).
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When installing the CVVT assembly bolt, hold the camshaft with
a wrench to prevent the camshaft from rotating.
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| 6. |
Remove the camshaft.
| (1) |
Remove the front camshaft bearing cap (A) with the upper bearing.
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| (2) |
Remove the camshaft bearing caps in the sequence shown.
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| (3) |
Remove the camshafts (A).
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| (4) |
Remove the exhaust camshaft lower bearing (A).
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CVVT Assembly
| 1. |
Inspect the CVVT for smooth rotation.
| (1) |
Clamp the camshaft using a vise. Be careful not to damage the
cam lobes and journals in the vise.
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| (2) |
Check that the CVVT is locked by turning it clockwise or counterclockwise.
It must not rotate.
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| (3) |
Exhaust CVVT : Seal one of the two retard holes in the camshaft
journal with tape.
[Exhaust]
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| (4) |
Exhaust CVVT : Apply approx. 150 kPa (1.5 kgf/cm², 21 psi ) of
compressed air into the unsealed retard hole to release the lock.
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Cover the oil paths with a piece of cloth when applying
compressed air to prevent oil from spraying.
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| (5) |
Exhaust CVVT : With compressed air applied, rotate the CVVT into
the retard direction (clockwise) and check that the CVVT turns smoothly.
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CVVT phasing range
Exhaust : 22.5°±1° (from the most advanced position to
the most retarded position)
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| (6) |
Exhaust CVVT : Rotate the CVVT into the most advanced position
(counterclockwise) and then check that the CVVT is locked.
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Camshaft
| 1. |
Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
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Cam height
[Standard value]
Intake : 44.10 - 44.30 mm (1.7362 - 1.7440 in.)
Exhaust : 44.90 - 45.10 mm (1.7677 - 1.7756 in.)
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If the cam lobe height is less than standard, replace the camshaft.
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| 2. |
Inspect the camshaft journal clearance.
| (1) |
Clean the bearing caps and camshaft journals.
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| (2) |
Place the camshafts on the cylinder head.
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| (3) |
Lay a strip of plastigage across each of the camshaft journal.
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| (4) |
Install the bearing caps.
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Do not turn the camshaft.
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| (5) |
Remove the bearing caps.
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| (6) |
Measure the plastigage at its widest point.
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Bearing oil clearance
[Standard value]
Intake :
No.1 : 0.029 - 0.057 mm (0.00114 - 0.00224 in.)
No.2, 3, 4, 5 : 0.037 - 0.067 mm (0.00146 - 0.00264 in.)
Exhaust:
No.1 : 0.004 - 0.036 mm (0.00016 - 0.00142 in.)
No.2,3,4,5 : 0.037 - 0.067 mm (0.00146 - 0.00264 in.)
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If the oil clearance is greater than maximum, replace the camshaft.
If necessary, replace cylinder head.
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| (7) |
Completely remove the plastigage.
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| (8) |
Remove the camshafts.
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| 3. |
Inspect the camshaft end play.
| (1) |
Install the camshafts.
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| (2) |
Using a dial indicator, measure the end play while moving the
camshaft back and forth.
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Camshaft end play
[Standard value] : 0.04 - 0.16 mm (0.0016 - 0.0063 in.)
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If the end play is greater than maximum, replace the camshaft.
If necessary, replace cylinder head.
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| (3) |
Remove the camshafts.
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| 1. |
Install the exhaust camshaft lower bearing (A).
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Apply a light coat of engine oil on camshaft journals.
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| 2. |
Install the camshafts (A).
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| 3. |
Install the exhaust camshaft upper bearing (A) to the camshaft front
bearing cap.
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| 4. |
Install the camshaft bearing caps.
| (1) |
Using a gasket scraper, remove all the old packing material from
the gasket surfaces.
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| (2) |
The sealant locations on the cylinder head and the counter parts
(front camshaft bearing cap) must be free of harmful foreign materials,
oil, dust and moisture. Spraying cleaner on the surface and wiping
with a clean duster.
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| (3) |
Before assembling the front camshaft bearing cap, liquid sealant
should be applied on the cylinder head surfaces.
The part must be assembled within 5 minutes after sealant was
applied.
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Bead width
Section A : 2.0 - 3.0 mm (0.08 - 0.12 in.)
Section B : 1.5 - 2.5 mm (0.06 - 0.10 in.)
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| 5. |
Install camshaft bearing caps (A) in their proper locations.
Tightening order
Group A → Group B → Group C.
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Tightening torque :
Step 1
M6 : 5.9 N·m (0.6 kgf·m, 4.3 lb·ft, 52.7 lb·in)
M8 : 14.7 N·m (1.5 kgf·m, 10.8 lb·ft)
Step 2
M6 : 10.8 - 12.7 N·m (1.1 - 1.3 kgf·m, 8.0 - 9.4 lb·ft)
M8 : 27.5 - 31.4 N·m (2.8 - 3.2 kgf·m, 20.3 - 23.1 lb·ft)
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Be careful not to change the position and direction of bearing
caps.
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| 6. |
Install the intake E-CVVT assembly (A) and exhaust CVVT assembly (B).
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Tightening torque :
Intake E-CVVT Assembly
73.5 - 83.4 N·m (7.5 - 8.5 kgf·m, 54.2 - 61.5 lb·ft)
Exhaust CVVT Assembly
53.9 - 63.7 N·m (5.5 - 6.5 kgf·m, 39.7 - 47.0 lb·ft)
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When installing the CVVT assembly bolt, hold the camshaft with
a wrench to prevent the camshaft (A) from rotating.
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When installing the CVVT assembly bolt, hold the camshaft with
a wrench to prevent the camshaft from rotating.
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| 7. |
Install the fuel pump bracket (A).
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Tightening torque :
18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)
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| 8. |
Install the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
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| 9. |
Install the timing chain cover.
(Refer to Timing System - "Timing Chain Cover")
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| 10. |
Clean the E-CVVT motor plug mounting surface (A) with oil cleaner.
| •
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If the surface is not cleaned, E-CVVT motor plug may
be separated due to diminished separation force from residual
oil.
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| •
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When spraying oil cleaner, block around the motor shaft
inlet and rotor gap with a clean towel to prevent inflow
of oil from flowing into the rotor gap.
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| 11. |
When reusing the E-CVVT cover, inspect the below items.
| (1) |
If there is sign of leakage from inside the E-CVVT cover, replace
it with a new one.
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| (2) |
Check for worn connector brush.
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Specification : Over 5 mm (0.1969 in.)
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If measurement is below specification, replace the E-CVVT cover
with a new one.
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| (3) |
Check for damaged oil seal (A) and replace any damaged E-CVVT
cover with a new one.
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| (4) |
After inspecting E-CVVT, if no problem is found, replace the
o-ring (A) with a new one.
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| 12. |
Install the E-CVVT cover.
| (1) |
Apply engine oil on oil seal lip (A).
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When applying oil, keep the connector brush (A) clean
from foreign materials.
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| (2) |
Insert SST (09243-C2000) into the E-CVVT motor shaft.
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Correctly mount SST onto the motor shaft.
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| (3) |
Slowly push the E-CVVT cover (A) until it is flush with the timing
chain cover surface.
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Installing the E-CVVT cover without SST may cause oil
leakage inside the E-CVVT motor due to damaged or separated
E-CVVT oil seal.
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| (4) |
Pre-tighten the bolts in the below sequence, and then remove
the SST (09243-C2000).
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Tightening torque :
1.0 - 2.0 N·m (0.1 - 0.2 kgf·m, 0.7 - 1.4 lb·ft, 8.7
- 17.4 lb·ft)
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| (5) |
Tighten the bolts to the specified torque in the sequence below.
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Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
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| 13. |
Install the E-CVVT plug.
| (1) |
By using SST (09243-C2000), insert the plug (A) into the E-CVVT
cover hole.
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Do not reuse a E-CVVT motor plug.
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| (2) |
Mount the stopper of SST so that it sits at the end of E-CVVT
motor shaft.
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| 14. |
Inspect the pressed depth of E-CVVT plug.
| (1) |
By using a steel ruler, measure the distance from E-CVVT cover
center boss to the end of motor shaft (①).
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| (2) |
By using a steel ruler, measure the distance from E-CVVT cover
center boss to the end of E-CVVT plug (②).
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| (3) |
Calculate the pressed depth (③) of motor plug.
If out of specification, reinstall after replacing the E-CVVT
plug with a new one.
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Pressed depth : ③ = ② - ①
Specification : 1.9 - 2.1 mm (0.0748 - 0.0827 in.)
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| 15. |
Insert the E-CVVT cover plug so that the protrusion (A) reach to E-CVVT
cover groove correctly.
| •
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Check how much protrude after installing the E-CVVT plug.
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| •
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Be careful that the plug is not inserted inside E-CVVT
cover beyond the regulated range.
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| 16. |
Install the other parts in the reverse order of removal.
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When replacing and reinstalling the electronic E-CVVT assembly,
make sure reset the value of learning using additional function
menu of KDS/GDS diagnostic
(Refer to Engine Control/Fuel System - "E-CVVT motor")
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Repair procedures
Removal
•
Use fender covers to avoid damaging painted surfaces.
...
Repair procedures
Removal
In case of removing the high pressure fuel pump, high pressure fuel pipe,
delivery pip ...
Other information:
Repair procedures
Removal
1.
Remove wheel nuts, wheel and tire (A) from hub.
Tightening torque:
107.9 - 127.5 N·m (11.0 - 13.0 kgf·m, 79.6 - 94.0 lb·ft)
...
Components and components location
Components
Repair procedures
Removal
lf replacement of the bracket or extension wire of BCW unit is required,
it is recommended to surely replace the defective ...
Cylinder Head Cover
Cylinder Head