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Home >> Kia >> 2014 >> Optima EX >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 76 (Timing System - 2.0L - Optima) >> Timing Chain >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.
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.
WARNING: In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.
  1. Remove the engine cover.
    Fig 1: Engine Cover
    G00549946Courtesy of KIA MOTORS AMERICA, INC.
  2. Disconnect the battery negative terminal (A).
  3. Remove the air duct (B) after removing the mounting bolts.
    Fig 2: Battery Negative Terminal & Air Duct
    G07383325Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the battery (A) after removing the mounting bracket (B).

    5. Tightening torque: 

    8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

    Fig 3: Battery & Mounting Bracket
    G00549947Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the air cleaner assembly.
    1. Disconnect the breather hose (A), the recirculation hose (B) and the brake booster vacuum hose (C).
    2. Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
      Fig 4: Breather Hose, Intensifier Hose, Brake Booster Vacuum Hose & Air Intake Hose
      G07383326Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the intercooler inlet hose (A).
    Fig 5: Intercooler Inlet Hose
    G07383327Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the recirculation valve connector (A) and the vacuum hose (B), and then remove the intercooler inlet pipe & hose assembly (C)
    Fig 6: Recirculation Valve Connector, Vacuum Hose, Intercooler Inlet Pipe & Hose Assembly
    G07383328Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the RH front wheel.
  9. Remove the under covers (A, B).
    Fig 7: Under Covers
    G07383329Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When removing the under cover (B), unfasten the mounting bracket bolts and then remove the under cover and mounting bracket assembly.
  10. Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover to set the piston of No. 1 cylinder to the top dead center on compression stroke.
    Fig 8: Identifying Timing Marks
    G07383330Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B).
    Fig 9: Oil Control Valve & Oxygen Sensor Connectors
    G07383331Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the ignition coil connectors (A) and the fuel pump connector (B), then remove the wiring protector.
    Fig 10: Ignition Coil & Fuel Pump Connectors
    G07383332Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the ignition coils (A).
    Fig 11: Ignition Coils
    G07383333Courtesy of KIA MOTORS AMERICA, INC.
  14. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
    Fig 12: Fuel Hose & PCSV Hose
    G07383334Courtesy of KIA MOTORS AMERICA, INC.
  15. Disconnect PCSV (Purge control solenoid valve) connector (A) and loosen the vacuum pipe assembly mounting bolts and nut.
    Fig 13: Purge Control Solenoid Valve Connector & Mounting Bolts
    G07383335Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the high pressure pipe (A). Refer to HIGH PRESSURE FUEL PUMP .
    Fig 14: High Pressure Pipe
    G07383336Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the high pressure fuel pump (A) and the roller tappet (B). Refer to HIGH PRESSURE FUEL PUMP .
    Fig 15: High Pressure Fuel Pump & Roller Tappet
    G07383337Courtesy of KIA MOTORS AMERICA, INC.
  18. Disconnect the PCV (Positive crankcase ventilation) hose (A) and then remove the front engine hanger (B).
    Fig 16: PCV Hose & Front Engine Hanger
    G07383338Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the cylinder head cover (A).
    Fig 17: Cylinder Head Cover
    G07383339Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
    Fig 18: Drive Belt, Tensioner & Belt Routing
    G07383340Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the A/C compressor lower bolts (A).
    Fig 19: A/C Compressor Lower Bolts
    G07383341Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the A/C compressor bracket (A).
    Fig 20: A/C Compressor Bracket
    G07383342Courtesy of KIA MOTORS AMERICA, INC.
  23. Drain the engine oil.
  24. Remove the oil pan (A). Insert the blade of SST (09215-3C000) between the ladder frame and oil pan. Cut off applied sealer and remove the lower oil pan.
    Fig 21: Removing Oil Pan Using Blade Of SST
    G07383343Courtesy 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 turn over the SST abruptly without tapping. It is result in damage of the SST.
    • Be careful not to damage the contact surfaces of ladder frame and lower oil pan.
  25. Set the jack to the edge of ladder frame.
    NOTE: Put the wooden block between ladder frame and jack.
    CAUTION: Be careful not to damage the balance shaft & oil pump module.
  26. Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
    Fig 22: Ground Line & Engine Mounting Support Bracket
    G07383344Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D).
    Fig 23: Idler, Water Pump Pulley, Crankshaft Pulley & Drive Belt Tensioner Pulley
    G07383345Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: Tensioner pulley bolt is left-handed screw.
    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 24: Ring Gear Stopper
    G07383346Courtesy of KIA MOTORS AMERICA, INC.

    * Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.

    1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
      2. Fig 25: Identifying Dust Cover And Mounting Bolts
      G00549948Courtesy of KIA MOTORS AMERICA, INC.
    2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
    3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
      4. Fig 26: Identifying SST (09231-3D100) Installation
      G00549949Courtesy of KIA MOTORS AMERICA, INC.
    4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
      5. Fig 27: Identifying (09231-3D100) Ring Gear Stopper
      G00549953Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the drive belt tensioner (A).
    Fig 28: Drive Belt Tensioner
    G07383347Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the engine support bracket (A).
    Fig 29: Engine Support Bracket
    G07383348Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block.
    Fig 30: Timing Chain Cover
    G07383349Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
  31. Make sure that the key (A) of crankshaft is aligned with the mating surface of main bearing cap. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.
    Fig 31: Identifying Crankshaft Key
    G07383350Courtesy of KIA MOTORS AMERICA, INC.
  32. Release the ratchet by pulling the link down using a thin rod. Compress the piston and then insert a stopper pin (A) into the hole on the ratchet to hold the compressed piston. Remove the timing chain tensioner (B).
    Fig 32: Identifying Stopper Pin & Timing Chain Tensioner
    G07383351Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the timing chain tensioner arm (A).
    Fig 33: Timing Chain Tensioner Arm
    G07383352Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the timing chain (A).
    Fig 34: Timing Chain
    G07383353Courtesy of KIA MOTORS AMERICA, INC.
  35. Remove the timing chain guide (A).
    Fig 35: Timing Chain Guide
    G07383354Courtesy of KIA MOTORS AMERICA, INC.
  36. Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).
    Fig 36: Timing Chain Oil Jet & Crankshaft Chain Sprocket
    G07383355Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the balance shaft chain. Refer to BALANCE SHAFT & OIL PUMP .
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