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

Disconnect the battery negative cable (A).

Fig 1: Disconnecting Battery Negative Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine cover (A).

Fig 2: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake air hose and air cleaner assembly.
1. Disconnect the MAF sensor connector (A).
2. Disconnect the breather hose (B) from air intake hose.
3. Remove the intake air hose and air cleaner assembly (C).
  
  Fig 3: Identifying MAF Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH front wheel.
Remove the under cover (A).

Fig 4: Identifying Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the side cover.
Loosen the drain plug and drain the engine coolant.
Drain the engine oil.
Remove the surge tank.
1. Disconnect the RH oxygen sensor connector (A) and loosen the power steering hose mounting bolts (B).
  
  Fig 5: Identifying RH Oxygen Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the RH injector connector (A) and ignition coil connector (B).
  
  Fig 6: Identifying RH Injector Connector
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.
  
  Fig 7: Identifying PCSV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the ETC connector (A) and knock sensor connector (B).
  
  Fig 8: Identifying ETC Connector
  Courtesy of KIA MOTORS AMERICA, INC.
5. Disconnect the OCV connector (A) and knock sensor connector (B).
  
  Fig 9: Identifying OCV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
6. Disconnect the LH front oxygen sensor connector (A).
  
  Fig 10: Identifying LH Front Oxygen Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D), and remove the wiring harness protector (E).
  
  Fig 11: Identifying LH Ignition Coil Connector
  Courtesy of KIA MOTORS AMERICA, INC.
8. Disconnect the LH CMPS (A) and oil pressure switch connector (B).
  
  Fig 12: Identifying LH CMPS
  Courtesy of KIA MOTORS AMERICA, INC.
9. Remove the ETC bracket (A).
10. Disconnect the water hoses (B) from ETC.
11. Disconnect the PCV hose (C).
  
  Fig 13: Identifying ETC Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
12. Disconnect the brake vacuum hose.
13. Remove the surge tank stay (A).
  
  Fig 14: Identifying Surge Tank Stay
  Courtesy of KIA MOTORS AMERICA, INC.
14. Remove the connector bracket (A) from surge tank.
  
  Fig 15: Identifying Connector Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
15. Remove the surge tank (A).
  
  Fig 16: 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.
Remove the cylinder head cover.
1. Remove the connector bracket (A) from LH cylinder head cover.
  
  Fig 17: Identifying Connector Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the RH ignition coil connector (A), condenser connector (B) and remove the wiring bracket (C).
  
  Fig 18: Identifying RH Ignition Coil Connector
  Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the LH, RH ignition coil.
4. Remove the LH, RH cylinder head cover (A).
  
  Fig 19: Identifying RH Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
Using SST (09215-3C000) remove lower oil pan (A).

Fig 20: Identifying Lower Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
Set a jack to the upper oil pan.

Fig 21: Identifying Upper Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
Remove the coolant reservoir tank.
Remove the engine mounting bracket (A).

Fig 22: Identifying Engine Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Set No. 1 cylinder to TDC/compression.
1. Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.
  NOTE: Do not rotate engine counterclockwise.
  
  Fig 23: Identifying Crankshaft Pulley Groove
  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 one revolution (360°).
  
  Fig 24: Identifying Mark On Camshaft Timing Sprockets
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Do not rotate engine counterclockwise.
Remove the drive belt (A).

Fig 25: Identifying Drive Belt
Courtesy of KIA MOTORS AMERICA, INC.
Using SST (09231-3C300) remove the crankshaft damper pulley (A).

Fig 26: Identifying Crankshaft Damper Pulley
Courtesy of KIA MOTORS AMERICA, INC.

Fig 27: Identifying Special Tool
Courtesy of KIA MOTORS AMERICA, INC.
Lift up the engine assembly to using the jack.
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.
Remove the timing chain cover (A).

Fig 31: Identifying Timing Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
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.
Install a set pin after compressing the timing chain tensioner.

Fig 32: Installing Set Pin
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH cam-to-cam guide (A).

Fig 33: Identifying RH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).

Fig 34: Identifying RH Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH timing chain.
Remove the RH timing chain guide (A).

Fig 35: Identifying RH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain cover (A).

Fig 36: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain tensioner assembly (A).

Fig 37: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain guide (A).

Fig 38: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil pump chain sprocket (A) and oil pump chain (B).

Fig 39: Identifying Oil Pump Chain Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

Fig 40: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install a set pin after compressing the LH timing chain tensioner.

Fig 41: Installing Set Pin
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LH cam-to-cam guide (A).

Fig 42: Identifying LH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).

Fig 43: Identifying LH Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Remove the LH timing chain.
Remove the LH timing chain guide (A).

Fig 44: Identifying LH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Remove the crankshaft sprocket (A) (LH camshaft drive).

Fig 45: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the tensioner adapter assembly (A).

Fig 46: Identifying Tensioner Adapter Assembly
Courtesy of KIA MOTORS AMERICA, INC.