Kia Stinger: Cylinder Head Assembly / CVVT & Camshaft

Kia Stinger CK 2018-2020 Service Manual / Engine Mechanical System / Cylinder Head Assembly / CVVT & Camshaft

Description and operation
Description

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.

Operation

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.

Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1.

Remove the timing chain

(Refer to Timing System - "Timing chain")

2.

Remove the cylinder head cover.

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

3.

Remove the fuel pump bracket (A).

4.

Remove it by breaking the center of E-CVVT motor plug (A).

  

Remove after 30 minutes of switching "OFF" the ignition to drain out the oil inside the E-CVVT motor plug.

Do not tilt the front of engine (timing chain cover side) downward as residual oil may flow out during E-CVVT motor plug removal.

If oil flows out during E-CVVT motor plug removal, wipe off immediately and block the motor shaft inlet with a clean towel.

5.

Disconnect the intake E-CVVT assembly (A) and exhaust CVVT assembly (B).

  

When installing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.

6.

Remove the camshaft.

(1)

Remove the front camshaft bearing cap (A) with the upper bearing.

(2)

Remove the camshaft bearing caps in the sequence shown.

(3)

Remove the camshafts (A).

(4)

Remove the exhaust camshaft lower bearing (A).

Inspection

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.

(2)

Check that the CVVT is locked by turning it clockwise or counterclockwise. It must not rotate.

(3)

Exhaust CVVT : Seal one of the two retard holes in the camshaft journal with tape.

[Exhaust]

(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.

  

Cover the oil paths with a piece of cloth when applying compressed air to prevent oil from spraying.

(5)

Exhaust CVVT : With compressed air applied, rotate the CVVT into the retard direction (clockwise) and check that the CVVT turns smoothly.

CVVT phasing range

Exhaust : 22.5°±1° (from the most advanced position to the most retarded position)

(6)

Exhaust CVVT : Rotate the CVVT into the most advanced position (counterclockwise) and then check that the CVVT is locked.

Camshaft

1.

Inspect the cam lobes.

Using a micrometer, measure the cam lobe height.

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.)

If the cam lobe height is less than standard, replace the camshaft.

2.

Inspect the camshaft journal clearance.

(1)

Clean the bearing caps and camshaft journals.

(2)

Place the camshafts on the cylinder head.

(3)

Lay a strip of plastigage across each of the camshaft journal.

(4)

Install the bearing caps.

  

Do not turn the camshaft.

(5)

Remove the bearing caps.

(6)

Measure the plastigage at its widest point.

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.)

If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

(7)

Completely remove the plastigage.

(8)

Remove the camshafts.

3.

Inspect the camshaft end play.

(1)

Install the camshafts.

(2)

Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play

[Standard value] : 0.04 - 0.16 mm (0.0016 - 0.0063 in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

(3)

Remove the camshafts.

Installation
1.

Install the exhaust camshaft lower bearing (A).

  

Apply a light coat of engine oil on camshaft journals.

2.

Install the camshafts (A).

3.

Install the exhaust camshaft upper bearing (A) to the camshaft front bearing cap.

4.

Install the camshaft bearing caps.

(1)

Using a gasket scraper, remove all the old packing material from the gasket surfaces.

(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.

(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.

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.)

5.

Install camshaft bearing caps (A) in their proper locations.

Tightening order

Group A → Group B → Group C.

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)

  

Be careful not to change the position and direction of bearing caps.

6.

Install the intake E-CVVT assembly (A) and exhaust CVVT assembly (B).

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)

  

When installing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft (A) from rotating.

  

When installing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.

7.

Install the fuel pump bracket (A).

Tightening torque :

18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)

8.

Install the cylinder head cover.

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

9.

Install the timing chain cover.

(Refer to Timing System - "Timing Chain Cover")

10.

Clean the E-CVVT motor plug mounting surface (A) with oil cleaner.

  

If the surface is not cleaned, E-CVVT motor plug may be separated due to diminished separation force from residual oil.

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.

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.

(2)

Check for worn connector brush.

Specification : Over 5 mm (0.1969 in.)

If measurement is below specification, replace the E-CVVT cover with a new one.

(3)

Check for damaged oil seal (A) and replace any damaged E-CVVT cover with a new one.

(4)

After inspecting E-CVVT, if no problem is found, replace the o-ring (A) with a new one.

12.

Install the E-CVVT cover.

(1)

Apply engine oil on oil seal lip (A).

  

When applying oil, keep the connector brush (A) clean from foreign materials.

(2)

Insert SST (09243-C2000) into the E-CVVT motor shaft.

  

Correctly mount SST onto the motor shaft.

(3)

Slowly push the E-CVVT cover (A) until it is flush with the timing chain cover surface.

  

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.

(4)

Pre-tighten the bolts in the below sequence, and then remove the SST (09243-C2000).

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)

(5)

Tighten the bolts to the specified torque in the sequence below.

Tightening torque :

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

13.

Install the E-CVVT plug.

(1)

By using SST (09243-C2000), insert the plug (A) into the E-CVVT cover hole.

  

Do not reuse a E-CVVT motor plug.

(2)

Mount the stopper of SST so that it sits at the end of E-CVVT motor shaft.

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).

(2)

By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of E-CVVT plug (②).

(3)

Calculate the pressed depth (③) of motor plug.

If out of specification, reinstall after replacing the E-CVVT plug with a new one.

Pressed depth : ③ = ② - ①

Specification : 1.9 - 2.1 mm (0.0748 - 0.0827 in.)

15.

Insert the E-CVVT cover plug so that the protrusion (A) reach to E-CVVT cover groove correctly.

  

Check how much protrude after installing the E-CVVT plug.

Be careful that the plug is not inserted inside E-CVVT cover beyond the regulated range.

16.

Install the other parts in the reverse order of removal.

  

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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