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Home › Kia › 2012 › Optima LX, Automatic Trans › Repair and Diagnosis › External Pages › Different variant/trim › Section 70 (Timing System - 2.0L) › 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.
  2. Disconnect the battery negative terminal (A).
  3. Remove the air duct (B).
    Fig 1: Battery Negative Terminal & Air Duct
    G07383325Courtesy of KIA MOTORS AMERICA, INC.
  4. 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 2: Breather Hose, Intensifier Hose, Brake Booster Vacuum Hose & Air Intake Hose
      G07383326Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the intercooler inlet hose (A).
    Fig 3: Intercooler Inlet Hose
    G07383327Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the recirculation valve connector (A) and the vacuum hose (B), and then remove the intercooler inlet pipe & hose assembly (C)
    Fig 4: Recirculation Valve Connector, Vacuum Hose, Intercooler Inlet Pipe & Hose Assembly
    G07383328Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the RH front wheel.
  8. Remove the under covers (A, B).
    Fig 5: 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.
  9. 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 6: Identifying Timing Marks
    G07383330Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B).
    Fig 7: Oil Control Valve & Oxygen Sensor Connectors
    G07383331Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the ignition coil connectors (A) and the fuel pump connector (B), then remove the wiring protector.
    Fig 8: Ignition Coil & Fuel Pump Connectors
    G07383332Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the ignition coils (A).
    Fig 9: Ignition Coils
    G07383333Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).
    Fig 10: Fuel Hose & PCSV Hose
    G07383334Courtesy of KIA MOTORS AMERICA, INC.
  14. Disconnect PCSV (Purge control solenoid valve) connector (A) and loosen the vacuum pipe assembly mounting bolts and nut.
    Fig 11: Purge Control Solenoid Valve Connector & Mounting Bolts
    G07383335Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the high pressure pipe (A). Refer to HIGH PRESSURE FUEL PUMP .
    Fig 12: High Pressure Pipe
    G07383336Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the high pressure fuel pump (A) and the roller tappet (B). Refer to HIGH PRESSURE FUEL PUMP .
    Fig 13: High Pressure Fuel Pump & Roller Tappet
    G07383337Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the PCV (Positive crankcase ventilation) hose (A) and then remove the front engine hanger (B).
    Fig 14: PCV Hose & Front Engine Hanger
    G07383338Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the cylinder head cover (A).
    Fig 15: Cylinder Head Cover
    G07383339Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the drive belt (A) after turning the drive belt tensioner (B) counterclockwise.
    Fig 16: Drive Belt, Tensioner & Belt Routing
    G07383340Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the A/C compressor lower bolts (A).
    Fig 17: A/C Compressor Lower Bolts
    G07383341Courtesy of KIA MOTORS AMERICA, INC.
  21. Remove the A/C compressor bracket (A).
    Fig 18: A/C Compressor Bracket
    G07383342Courtesy of KIA MOTORS AMERICA, INC.
  22. Drain the engine oil.
  23. 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 19: 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.
  24. 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.
  25. Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
    Fig 20: Ground Line & Engine Mounting Support Bracket
    G07383344Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D).
    Fig 21: 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: Use the SST (Ring gear stopper, 09231-3K000) (A) to remove the crankshaft pulley bolt, after removing the starter.
    Fig 22: Ring Gear Stopper
    G07383346Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drive belt tensioner (A).
    Fig 23: Drive Belt Tensioner
    G07383347Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the engine support bracket (A).
    Fig 24: Engine Support Bracket
    G07383348Courtesy of KIA MOTORS AMERICA, INC.
  29. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block.
    Fig 25: 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.
  30. 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 26: Identifying Crankshaft Key
    G07383350Courtesy of KIA MOTORS AMERICA, INC.
  31. 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 27: Identifying Stopper Pin & Timing Chain Tensioner
    G07383351Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the timing chain tensioner arm (A).
    Fig 28: Timing Chain Tensioner Arm
    G07383352Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the timing chain (A).
    Fig 29: Timing Chain
    G07383353Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the timing chain guide (A).
    Fig 30: Timing Chain Guide
    G07383354Courtesy of KIA MOTORS AMERICA, INC.
  35. Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).
    Fig 31: Timing Chain Oil Jet & Crankshaft Chain Sprocket
    G07383355Courtesy of KIA MOTORS AMERICA, INC.
  36. Remove the balance shaft chain. Refer to BALANCE SHAFT & OIL PUMP .
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