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Home >> Kia >> 2015 >> Rio LX, 4D Hatchback, Automatic Trans >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Timing System >> Timing Chain >> Repair Procedures >> Removal

Repair Procedures: Removal

Engine removal is not required for this procedure.

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 mis-connection.
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.
  2. Disconnect the battery negative terminal (A).
    Fig 1: Identifying Battery Negative Terminal
    G08320903Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the air cleaner assembly.
    1. Remove the air duct (A).
    2. Disconnect the breather hose (B).
    3. Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
    Fig 2: Identifying Air Duct, Breather Hose, Air Intake Hose And Air Cleaner Assembly
    G08320904Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the RH front wheel.
  5. Remove the under covers (A).
    Fig 3: Identifying Under Covers Bolts
    G08320905Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C).
    Fig 4: Identifying A/C Compressor Switch Connector, Alternator Connector And Alternator Terminal
    G08320906Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B).
    Fig 5: Identifying Intake OCV Connector And Exhaust OCV Connector
    G08320907Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D).
    Fig 6: Identifying Ignition Coil Connectors, Injector Extension Connector, VIS Connector And PCSV Connector
    G08320908Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C).
    Fig 7: Identifying FPCV Connector, Intake CMPS Connector And Exhaust CMPS Connector
    G08320909Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the oxygen sensor connectors (A) and the condenser connector (B).
    Fig 8: Identifying Oxygen Sensor Connectors And Condenser Connector
    G08320910Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the fuel hose (A) and the PCV (Positive crankcase ventilation) hose (B).
    Fig 9: Identifying Fuel Hose And PCV Hose
    G08320911Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the vacuum pipe assembly (A).
    Fig 10: Identifying Vacuum Pipe Assembly
    G08320912Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the high pressure pipe (A). (Refer to DELIVERY PIPE FL group)
    Fig 11: Identifying High Pressure Pipe
    G08320913Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the high pressure fuel pump (A) and the roller tappet (B). (Refer to HIGH PRESSURE FUEL PUMP FL group)
    Fig 12: Identifying High Pressure Fuel Pump And Roller Tappet
    G08320914Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the ignition coils (A).
    Fig 13: Identifying Ignition Coils
    G08320915Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the exhaust OCV (Oil control valve) (B).
    Fig 14: Identifying Exhaust OCV (Oil Control Valve)
    G08320916Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the cylinder head cover (A) with gaskets (B).
    Fig 15: Identifying Cylinder Head Cover And Gaskets
    G08320917Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the exhaust OCV (Oil control valve) adapter (A).
    Fig 16: Identifying Exhaust OCV (Oil Control Valve) Adapter
    G08320918Courtesy of KIA MOTORS AMERICA, INC.
  19. Loosen the water pump pulley bolt and the drive idler mounting bolt.
  20. Loosen the alternator tension adjusting bolt (A) to loosen tension.
    Fig 17: Loosening Alternator Tension Adjusting Bolt
    G08320919Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the alternator drive belt (A).
    Fig 18: Identifying Alternator Drive Belt
    G08320920Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the alternator (A). (Refer to ALTERNATOR Alternator in EE Group).
    Fig 19: Identifying Alternator
    G08320921Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the ground line (A) and then remove the engine mounting support bracket (A).
    Fig 20: Identifying Ground Line And Engine Mounting Support Bracket
    G08320922Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Support the engine with a jack not to be tilted.
  24. Remove the alternator bracket (B).
  25. Remove the engine support bracket (A).
    Fig 21: Identifying Alternator Bracket And Engine Support Bracket
    G08320923Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the water pump pulley (A) and the drive belt idler (B).
    Fig 22: Identifying Water Pump Pulley And Drive Belt Idler
    G08320924Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the water pump (A).
    Fig 23: Identifying Water Pump
    G08320925Courtesy of KIA MOTORS AMERICA, INC.
  28. Turn the crankshaft pulley clockwise, and align its groove with the timing mark of the timing chain cover.
    Fig 24: Identifying Timing Chain Cover Timing Mark
    G08320926Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the crankshaft bolt (B) and crankshaft pulley (A).
    Fig 25: Identifying Crankshaft Bolt And Crankshaft Pulley
    G08320927Courtesy 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 26: Holding Ring Gear Using SST (09231-2B100)
      G08320928Courtesy of KIA MOTORS AMERICA, INC.
    • Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
    1. Remove the bracket (A).
      Fig 27: Identifying Bracket
      G08320929Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the dust cover (A) and unfasten the transaxle mounting bolt (B).
      Fig 28: Identifying Dust Cover And Transaxle Mounting Bolt
      G08320930Courtesy of KIA MOTORS AMERICA, INC.
    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. Adjust the angle of the links (D), and fasten the bolt 70mm(2.7559in) in the original mounted hole.
      Fig 29: Identifying Holder Nuts, Holder, Ring Gear And Links
      G08320931Courtesy of KIA MOTORS AMERICA, INC.
    5. Tighten the bolts and nuts of the holder and links securely.
    Fig 30: Identifying Holder And Links
    G08320932Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the timing chain cover (A).
    Fig 31: Identifying Timing Chain Cover
    G08320933Courtesy of KIA MOTORS AMERICA, INC.
  31. Align the timing marks of the Continuous variable valve timing (CVVT) sprockets with the upper surface of the cylinder head to make No. 1 cylinder be positioned at top dead Center (TDC).
    1. Check the dowel pin of the crankshaft for facing upside of the engine at this moment.
    CAUTION: Put paint marks on the timing chain links(3 places) that meet with the timing marks of the CVVT sprockets (In, Ex: 2) and the CVVT sprocket.
    Fig 32: Identifying Timing Marks Of CVVT Sprockets
    G08320934Courtesy of KIA MOTORS AMERICA, INC.
    Fig 33: Identifying Timing Marks Of Crank Sprocket
    G08320935Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the hydraulic tensioner (A).
    Fig 34: Identifying Hydraulic Tensioner
    G08320936Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: Before removing the tensioner, fix the piston of the tensioner with a pin through the hole(B) at compressed position.
  33. Remove the timing chain tensioner arm (A) and guide (B).
    Fig 35: Identifying Timing Chain Tensioner Arm And Guide
    G08320937Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the timing chain (A).
Fig 36: Identifying Timing Chain
G08320938Courtesy of KIA MOTORS AMERICA, INC.
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