Author Topic: Valve cover gasket replacement 1.6 crdi  (Read 370 times)

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Valve cover gasket replacement 1.6 crdi
« October 30, 2017, 16:22:12 »
Hello

Perhaps a stupid question, but still...
Must injectors be completely removed when replacing valve cover gasket on CRDI 1.6 kia ceed (model 2007) ?
Is there any detailed guide on here about injectors removal? Do we need any special tool for that?

Thanks and kind regards.


  • kia ceed 2009, 1.6 crdi 85kw

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  • au Australia
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Re: Valve cover gasket replacement 1.6 crdi
« Reply #1 : October 31, 2017, 03:36:12 »
definitely not a silly question. I admire your bravery.  I'm sure I'll face this at some stage myself.

WOuld have to refer to a manual .

Remove the injector

Common Rail Fuel Injection System operates with extremely high pressure (approximately 1,600bar), so never perform any work on injection system with engine running or within 30 seconds after the engine stops.
● Keep cleanly the parts and the working area.
● Pay attention to a foreign substance.
● Just before installing injector, tube or hose, remove the protect-cap attached on them.
● Do not remove injector except for special case.
● When installing Injector
- Wash the contact area of the injector and replace the O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
● When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.

Disconnect the injector connector (A).

 
3. After removing the clip (B), disconnect the return hose (C) from the injectors.
4. Disconnect the high pressure fuel pipe (D) connecting the injectors with the common rail.
5. Unscrew the clamp tightening bolt (E) and pull the injector upward.

Note: If the injector adheres to the cylinder head, use the special Service Tool (SST No. : 09351-4A300)

When installing the injector, MUST REPLACE the O-ring (A) and apply a grease to that

When installing the high pressure fuel pipe, apply the specified tightening torques with the special service tool (Refer to below table).

Remove the cylinder head cover(A).

 


  • 2008 i30 SLX CRDi Auto, 2010 i30CW SLX CRDi Auto

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Re: Valve cover gasket replacement 1.6 crdi
« Reply #2 : November 01, 2017, 04:26:15 »
This can be a nightmare job if injectors are stuck in head. Then you will need injector puller and after that injector hole cleaner/reamer and new cooper washers for injector sealing.

Of course.. it also can be a 15 min job if injectors can be easily removed.

Before changing any gaskets take a look first at pcv system if it is working propertly
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Re: Valve cover gasket replacement 1.6 crdi
« Reply #3 : November 01, 2017, 11:42:47 »
Thanks both of you for the inputs.

And where exactly is the location of PCV valve?  Is it called by another name? Is this engine even has one?
I would greatly appreciate if you could mark it on the attached picture.

ns
« Last Edit: November 01, 2017, 12:00:20 by spaceone » »
  • kia ceed 2009, 1.6 crdi 85kw

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Re: Valve cover gasket replacement 1.6 crdi
« Reply #4 : November 01, 2017, 13:40:51 »
It is located od air intake tube few inches from turbocharger. You cant see it on this pic.
  • 1.6crdi

Re: Valve cover gasket replacement 1.6 crdi
« Reply #5 : November 04, 2017, 09:03:00 »
it also can be a 15 min job if injectors can be easily removed.

Heh, i spent 15 minutes only to find half of necessary tools....

Injectors went out rather easy. I've cleaned them with ultrasonic (for home usage). Replaced the valve cover gasket and put everything back together. At the moment looks good, fingers crossed.

So, PCV...
If I'm not mistaken PCV (or rather CCV?) is at the other end of the red marked hose, right?
ns

What's the optimal way to check, if it's working properly?
The same as with petrol engines? If there is sucking pressure at the valve cover side end,  then it's ok?

I actually have hard time finding any new PCV valve at online shops (in Europe at least) and also on ebay (if I'm even searching for the correct part - catalog number 26722-27000).

  • kia ceed 2009, 1.6 crdi 85kw

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Re: Valve cover gasket replacement 1.6 crdi
« Reply #6 : November 04, 2017, 19:40:49 »
26722-27000
Sounds like you're going well. That looks like a bit of pipe. have you had it out to check? possibly simply straight through.

that other bit, looks like PCV for petrol engines.

224042A001     PIPE
  • 2008 i30 SLX CRDi Auto, 2010 i30CW SLX CRDi Auto

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Re: Valve cover gasket replacement 1.6 crdi
« Reply #7 : November 05, 2017, 05:27:15 »


it also can be a 15 min job if injectors can be easily removed.

Heh, i spent 15 minutes only to find half of necessary tools....

Injectors went out rather easy. I've cleaned them with ultrasonic (for home usage). Replaced the valve cover gasket and put everything back together. At the moment looks good, fingers crossed.

So, PCV...
If I'm not mistaken PCV (or rather CCV?) is at the other end of the red marked hose, right?
ns

What's the optimal way to check, if it's working properly?
The same as with petrol engines? If there is sucking pressure at the valve cover side end,  then it's ok?

I actually have hard time finding any new PCV valve at online shops (in Europe at least) and also on ebay (if I'm even searching for the correct part - catalog number 26722-27000).

Yes pcv is connected on this hose. Just pull him out. To test pcv you just need to close both holes and shake it as hard you can. If you hear rattle like shaking small stones inside then it's all ok. If there is no sound then something is blocked inside.
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Re: Valve cover gasket replacement 1.6 crdi
« Reply #8 : November 11, 2017, 08:16:26 »
I've checked it today. No rattling noise and there was some oil in the tube. So I guess it's time to replace it.
Anybody knows an online shop in Europe to buy it from? 

  • kia ceed 2009, 1.6 crdi 85kw

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Re: Valve cover gasket replacement 1.6 crdi
« Reply #9 : November 11, 2017, 15:39:33 »
224042A001
I'd sure like to see an actual image of this valve you blokes are on about. Where exactly does it sit on this hose?
  • 2008 i30 SLX CRDi Auto, 2010 i30CW SLX CRDi Auto

Re: Valve cover gasket replacement 1.6 crdi
« Reply #10 : November 12, 2017, 05:18:14 »
Cat number 224042A001 is only a pipe, which connects the breathing hose to the valve cover.  It doesn't have any valve inside (based on the Kia Microcat ).

The actual pcv valve is 2672227000.
It's listed here :link: Auto Part Item View : 2672227000 (26722-27000) VALVE ASSY-CRANK CASE PCV for HYUNDAI / KIA TRAJET with picture.

I also took a couple of photos of it :
ns
ns

BTW: I've assumed the gasket started to leak, because the official KIA service always put to much oil into the engine (over max level) for last 6 years. Their response was always that it's ok...
« Last Edit: November 12, 2017, 06:11:44 by spaceone » »
  • kia ceed 2009, 1.6 crdi 85kw

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  • au Australia
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Re: Valve cover gasket replacement 1.6 crdi
« Reply #11 : November 12, 2017, 08:18:56 »
Cat number 224042A001 is only a pipe, which connects the breathing hose to the valve cover.  It doesn't have any valve inside (based on the Kia Microcat ).

The actual pcv valve is 2672227000.
It's listed here :link: Auto Part Item View : 2672227000 (26722-27000) VALVE ASSY-CRANK CASE PCV for HYUNDAI / KIA TRAJET with picture.

I also took a couple of photos of it :
ns
ns

BTW: I've assumed the gasket started to leak, because the official KIA service always put to much oil into the engine (over max level) for last 6 years. Their response was always that it's ok...

Sorry, just had to finish dinner.



Yep you're100% correct with that number. Sorry I'm so use to PCVs hanging offf the rocker cover. Never realised these had one, LOL  :mrgreen:
  • 2008 i30 SLX CRDi Auto, 2010 i30CW SLX CRDi Auto