Timing Chain: Removal

CAUTION:

Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE: Mark all wiring and hoses to avoid misconnection.

Disconnect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
Remove the engine cover (B).

Fig 1: Disconnecting Battery Negative Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A) and the BARO (Barometric pressure) sensor connector (B).
2. Disconnect the air intake hose and then remove the air cleaner assembly (C).
Tightening torque

Hose clamp bolt:

2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)

Air cleaner assembly bolts:

7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 2: Identifying Breather Hose
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Remove the under cover (A).

Fig 3: Identifying Under Cover
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Remove the RH front wheel and the side cover.
Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining.

Fig 4: Identifying Drain Plug
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WARNING: Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
Remove the radiator upper hose (A) and lower hose (B).

Fig 5: Identifying Radiator Upper Hose And Lower Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the wiring connectors, harness clamps and hoses from the engine.
1. Power steering pump oil pressure switch.
2. RH front, rear oxygen sensor connector (A) and loosen the power steering hose mounting bolts (B).
  
  Fig 6: Identifying Rear Oxygen Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
3. VIS connector (A).
4. RH exhaust camshaft OCV connector (B).
5. RH ignition coil connector (C).
6. RH injector connector (D).
  
  Fig 7: Identifying VIS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
7. LH exhaust camshaft OCV connector (A).
8. LH/RH intake camshaft OCV connector (B).
9. Oil pressure switch connector (C).
10. Knock sensor connector (D).
11. Condenser connector (E).
12. Ground (F).
13. LH front oxygen sensor connector (G).
14. Cooling box cable (H).
  
  Fig 8: Identifying Camshaft OCV Connector, Knock Sensor Connector And Cooling Box Cable
  Courtesy of KIA MOTORS AMERICA, INC.
15. Alternator connector (A).
  
  Fig 9: Identifying Alternator Connector
  Courtesy of KIA MOTORS AMERICA, INC.
16. LH ignition coil connectors (A).
17. LH injector connectors (B).
18. LH intake CMPS connector (C).
  
  Fig 10: Identifying Ignition Coil Connector, Injector Connector And CMPS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
19. MAP sensor connector (A).
20. PCSV connector (B).
  
  Fig 11: Identifying MAP Sensor Connector And PCSV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
21. RH intake CMPS connector (A).
22. ETC connector (B).
23. OTS connector (C).
24. Knock sensor connector (D).
25. RH exhaust CMPS connector (E).
  
  Fig 12: Identifying CMPS Connector, ETC Connector And Knock Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
26. WTS & gauge unit connector (A).
  
  Fig 13: Identifying WTS And Gauge Unit Connector
  Courtesy of KIA MOTORS AMERICA, INC.
27. LH exhaust CMPS connector (A).
28. LH rear oxygen sensor connector (B).
29. CKPS connector (C).
  
  Fig 14: Identifying CMPS Connector, Rear Oxygen Sensor Connector And CKPS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the PCSV hose (A), fuel hose (B), brake booster vacuum hose (C).

Fig 15: Identifying PCSV Hose, Fuel Hose, Brake Booster Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
Drain the engine oil.
Remove the lower oil pan (A).
Insert the blade of SST (09215-3C000) between the upper oil pan and lower oil pan. Cut off applied sealer and remove the lower oil pan.

Fig 16: Removing Lower Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not use the SST as a prybar. Hold the tool in position (on the gasket line) and tap in with a light hammer.
- Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
Install the jack to the edge of ladder frame (A) to support the engine.

Fig 17: Identifying Ladder Frame
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Insert the rubber block between jack and ladder frame.
Disconnect the ground cable (A), and then remove the engine mounting bracket (B).

Fig 18: Identifying Ground Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the surge tank (A). (Refer to INTAKE AND EXHAUST SYSTEM .)

Fig 19: Identifying Surge Tank
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
Disconnect the RH ignition coil connectors (A) and the RH injector connectors (B).

Fig 20: Identifying Ignition Coil Connectors And Injector Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LH/RH ignition coils (A).

Fig 21: Identifying Ignition Coil (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 22: Identifying Ignition Coil (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the exhaust OCV cap (A), and then remove the LH, RH cylinder head covers.

Fig 23: Identifying OCV Cap
Courtesy of KIA MOTORS AMERICA, INC.
To release the tension, turn the drive belt tensioner counterclockwise then remove the drive belt (A).

Fig 24: Identifying Drive Belt & Drive Belt Routing
Courtesy of KIA MOTORS AMERICA, INC.
Lift up the engine assembly by using the jack.
Remove the power steering pump (A). (Refer to POWER STEERING OIL PUMP .

Fig 25: Identifying Power Steering Pump
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air conditioner compressor (A). (Refer to COMPRESSOR .

Fig 26: Identifying Air Conditioner Compressor
Courtesy of KIA MOTORS AMERICA, INC.
Remove the alternator (A).

Fig 27: Identifying Alternator
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drive belt idler (A).

Fig 28: Identifying Drive Belt Idler
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drive belt auto tensioner (A).

Fig 29: Identifying Drive Belt Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the water pump pulley (A).

Fig 30: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.
  
  Fig 31: Identifying Timing Mark
  Courtesy of KIA MOTORS AMERICA, INC.
2. Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft clockwise one revolution (360°).
Fig 32: Identifying Mark Of Camshaft Timing Sprocket (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 33: Identifying Mark Of Camshaft Timing Sprocket (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not rotate engine counterclockwise.
Remove the crankshaft pulley (A).

Fig 34: Identifying Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 35: Installing SST (09231-2B100)
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
  1. Remove the front muffler. (Refer to INTAKE AND EXHAUST SYSTEM )
  2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
  Fig 36: Identifying Dust Cover
  Courtesy of KIA MOTORS AMERICA, INC.
- Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
- Fasten the two transaxle mounting bolts in the original mounted holes.
  
  Fig 37: Adjusting Length Of Holder Nut
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
  
  Fig 38: Installing SST (09231-3D100)
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the water pump (A) and gasket (B).

Fig 39: Identifying Water Pump And Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the timing chain cover (A).

Fig 40: Identifying Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

NOTE: Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.

Fig 41: Identifying Identification Mark On Chain (1 Of 4)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 42: Identifying Identification Mark On Chain (2 Of 4)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 43: Identifying Identification Mark On Chain (3 Of 4)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 44: Identifying Identification Mark On Chain (4 Of 4)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain cover (A).

Fig 45: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain tensioner assembly (A).

Fig 46: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain guide (A).

Fig 47: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install a set pin after compressing the RH timing chain tensioner.

Fig 48: Identifying Set Pin
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).

Fig 49: Identifying Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH timing chain guide (A) and RH timing chain (B).

Fig 50: Identifying Timing Chain Guide And Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain sprocket (A) and oil pump chain (B).

Fig 51: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
Courtesy of KIA MOTORS AMERICA, INC.
Remove the crankshaft sprocket (A) (O/P & RH camshaft drive).

Fig 52: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install a set pin after compressing the LH timing chain tensioner.

Fig 53: Identifying Set Pin
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Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

Fig 54: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LH timing chain guide (A) and LH timing chain (B).

Fig 55: Identifying Timing Chain Guide And Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.
Remove the crankshaft sprocket (A). (LH camshaft drive).

Fig 56: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the tensioner adapter assembly (A).

Fig 57: Identifying Tensioner Adapter Assembly

G07395565

Courtesy of KIA MOTORS AMERICA, INC.