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Home >> Kia >> 2008 >> Sedona LX >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Engine Mechanical >> Timing System >> Timing Chain >> Repair Procedure >> Removal

Repair Procedure: 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.
  1. Disconnect the battery negative cable (A).
    Fig 1: Identifying Battery Negative Cable
    G07900194
  2. Remove the engine cover (A).
    Fig 2: Identifying Engine Cover
    G07900195
  3. 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, Breather Hose And Air Cleaner Assembly
    G07900196
  4. Remove the RH front wheel.
  5. Remove the under cover (A).
    Fig 4: Identifying Under Cover
    G07900197
  6. Remove the side cover.
  7. Loosen the drain plug and drain the engine coolant.
  8. Drain the engine oil.
  9. 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 And Power Steering Hose Mounting Bolts
      G07900198
    2. Disconnect the RH injector connector (A) and ignition coil connector (B).
      Fig 6: Identifying RH Injector Connector And Ignition Coil Connector
      G07900199
    3. Disconnect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.
      Fig 7: Identifying PCSV Connector And MAP Sensor Connector
      G07900200
    4. Disconnect the ETC connector (A) and knock sensor connector (B).
      Fig 8: Identifying ETC Connector And Knock Sensor Connector
      G07900201
    5. Disconnect the OCV connector (A) and knock sensor connector (B).
      Fig 9: Identifying OCV Connector And Knock Sensor Connector
      G07900202
    6. Disconnect the LH front oxygen sensor connector (A).
      Fig 10: Identifying LH Front Oxygen Sensor Connector
      G07900203
    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, Injector Connector, Condenser Connector And Ground
      G07900204
    8. Disconnect the LH CMPS (A) and oil pressure switch connector (B).
      Fig 12: Identifying LH CMPS And Oil Pressure Switch Connector
      G07900205
    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, Water Hoses, And PCV Hose
      G07900206
    12. Disconnect the brake vacuum hose.
    13. Remove the surge tank stay (A).
      Fig 14: Identifying Surge Tank Stay
      G07900207
    14. Remove the connector bracket (A) from surge tank.
      Fig 15: Identifying Connector Bracket
      G07900208
    15. Remove the surge tank (A).
    Fig 16: Identifying Surge Tank
    G07900209
    NOTE: Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
  10. Remove the cylinder head cover.
    1. Remove the connector bracket (A) from LH cylinder head cover.
      Fig 17: Identifying Connector Bracket
      G07900210
    2. Disconnect the RH ignition coil connector (A), condenser connector (B) and remove the wiring bracket (C).
      Fig 18: Identifying RH Ignition Coil Connector, Condenser Connector And Wiring Bracket
      G07900211
    3. Remove the LH, RH ignition coil.
    4. Remove the LH, RH cylinder head cover (A).
    Fig 19: Identifying Cylinder Head Cover
    G07900212
  11. Using SST (09215-3C000) remove lower oil pan (A).
    Fig 20: Removing Lower Oil Pan Using SST (09215-3C000)
    G07900213
    NOTE: Be careful not to damage the contact surfaces of upper oil pan and lower oil pan.
  12. Set a jack to the upper oil pan.
    Fig 21: Locating Upper Oil Pan
    G07900214
  13. Remove the coolant reservoir tank.
  14. Remove the engine mounting bracket (A).
    Fig 22: Identifying Engine Mounting Bracket
    G07900215
  15. 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: Aligning Crankshaft Pulley Groove With Timing Mark
      G07900216
    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 Camshaft Timing Sprockets Mark
      G07900217
      NOTE: Do not rotate engine counterclockwise.
  16. Remove the drive belt (A).
    Fig 25: Identifying Drive Belt
    G07900218
  17. Remove the crankshaft damper pulley (A).
    Fig 26: Identifying Crankshaft Damper Pulley
    G07900219
    NOTE: There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
    • Install the SST (09231-3C300) to hold the ring gear after removing the starter.
      Fig 27: Holding Ring Gear Using SST (09231-3C300)
      G07900220
    • 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 28: Identifying Transaxle Mounting Bolts
      G07900221
    3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
    4. Fasten the two transaxle mounting bolts in the original mounted holes.
      Fig 29: Identifying Holder Nuts, Front Plate Holder, And Ring Gear Teeth
      G07900222
    5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
    Fig 30: Installing SST (09231-3D100) Using Two Mounting Bolts
    G07900223
  18. Lift up the engine assembly to using the jack.
  19. Remove the drive belt idler (A).
    Fig 31: Identifying Drive Belt Idler
    G07900224
  20. Remove the drive belt auto tensioner (A).
    Fig 32: Identifying Drive Belt Auto Tensioner
    G07900225
  21. Remove the water pump pulley (A).
    Fig 33: Identifying Water Pump Pulley
    G07900226
  22. Remove the timing chain cover (A).
    Fig 34: Identifying Timing Chain Cover
    G07900227
    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.
  23. Install a set pin after compressing the timing chain tensioner.
    Fig 35: Compressing Timing Chain Tensioner
    G07900228
  24. Remove the RH cam-to-cam guide (A).
    Fig 36: Identifying RH Cam-To-Cam Guide
    G07900229
  25. Remove the RH timing chain auto tensioner (A) and RH timing chain tensioner arm (B).
    Fig 37: Identifying RH Timing Chain Auto Tensioner And RH Timing Chain Tensioner Arm
    G07900230
  26. Remove the RH timing chain.
  27. Remove the RH timing chain guide (A).
    Fig 38: Identifying RH Timing Chain Guide
    G07900231
  28. Remove the oil pump chain cover (A).
    Fig 39: Identifying Oil Pump Chain Cover
    G07900232
  29. Remove the oil pump chain tensioner assembly (A).
    Fig 40: Identifying Oil Pump Chain Tensioner Assembly
    G07900233
  30. Remove the oil pump chain guide (A).
    Fig 41: Identifying Oil Pump Chain Guide
    G07900234
  31. Remove the oil pump chain sprocket (A) and oil pump chain (B).
    Fig 42: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
    G07900235
  32. Remove the crankshaft sprocket (A) (Oil pump&RH camshaft drive).
    Fig 43: Identifying Crankshaft Sprocket
    G07900236
  33. Install a set pin after compressing the LH timing chain tensioner.
    Fig 44: Installing Set Pin After Compressing LH Timing Chain Tensioner
    G07900237
  34. Remove the LH cam-to-cam guide (A).
    Fig 45: Identifying LH Cam-To-Cam Guide
    G07900238
  35. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
    Fig 46: Identifying LH Timing Chain Auto Tensioner And LH Timing Chain Tensioner Arm
    G07900239
  36. Remove the LH timing chain.
  37. Remove the LH timing chain guide (A).
    Fig 47: Identifying LH Timing Chain Guide
    G07900240
  38. Remove the crankshaft sprocket (A) (LH camshaft drive).
    Fig 48: Identifying Crankshaft Sprocket
    G07900241
  39. Remove the tensioner adapter assembly (A).
Fig 49: Identifying Tensioner Adapter Assembly
G07900242
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