Kia Picanto: Cylinder Head Assembly / Cylinder Head Cover

Kia Picanto JA 2017-2022 Service & Repair Manual / Engine Mechanical System / Cylinder Head Assembly / Cylinder Head Cover

Components and components location
Components

1. Oil filler cap
2. Cylinder head cover
3. Cylinder head cover gasket

Repair procedures
Removal
   
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
   
Mark all wiring and hoses to avoid misconnection.
1.
Disconnect the battery negative terminal.
2.
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
3.
Drain the engine coolant.
(Refer to Cooling System - "Coolant")
4.
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold and cylinder head cover.

5.
Disconnect the fuel hose (A).

6.
Remove the heated oxygen sensor (HO2S).
(Refer to Engine Control / Fuel System - "Heated Oxygen Sensor (HO2S)")
7.
Disconnect the coolant hose (A).

8.
Disconnect the turbo charger water drain hose (A).

9.
Remove the turbo manifold module heat protector (A).
Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
10.
Remove the turbo charger water pipe (B).
Tightening torque
Water pipe mounting bolt :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
Eye bolt :26.5 - 32.4 N·m (2.7 - 3.3 kgf·m, 19.5 - 23.9 lb·ft)

11.
Remove the heat protector (A) and engine hanger (B).
Tightening torque :
18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)

12.
Remove the high pressure fuel pump.
(Refer to Engine Control / Fuel System - "High Pressure Fuel Pump")
13.
Remove the ignition coil.
(Refer to Engine Electrical System - "Ignition Coil")
14.
Disconnect the positive crankcase ventilation (PCV) hose (A).

15.
Remove the cylinder head cover (A) with gasket.

Installation
1.
Install the new cylinder head cover gasket (A).

   
Do not reuse the cylinder head cover gasket.
2.
The hardening sealant on the upper area between chain cover & oil pump assembly and cylinder head should be removed before assembling cylinder head cover.
3.
Assemble within 5 minutes of applying sealant.
Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in.)

4.
Install the cylinder head cover (A).

5.
Install the cylinder head cover bolts in the following two step method.
Tightening torque
Step 1:
3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft)
Step 2:
7.8 - 9.8 N·m (0.8 - 1.0 kgf·m, 5.8 - 7.2 lb·ft)

   
The firing and/or blow out test should not be performed within 30 minutes of assembling the cylinder head cover.
6.
Install the remaining parts in the reverse order of removal.
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