Timing System: Removal & Installation Kia Carnival III

Removal

Note. Mark all wiring and hoses to avoid misconnection.

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1. Disconnect the battery negative terminal (A). Tightening torque: 4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
2. Remove the engine cover (B).
3. Remove the air cleaner assembly. Disconnect the breather hose (A) and the BARO (Barometric pressure) sensor connector (B). Disconnect the air intake hose and then remove the air cleaner assembly (C). Tightening torque Hose clamp bolt: 2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft) Air cleaner assembly bolts: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
4. Remove the under cover (A).
5. Remove the RH front wheel and the side cover.
6. Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining. WARNING: Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.
7. Remove the radiator upper hose (A) and lower hose (B).
8. Disconnect the wiring connectors, harness clamps and hoses from the engine. RH front, rear oxygen sensor connector (A). VIS connector (B). RH exhaust camshaft OCV connector (C). RH ignition coil connector (D). RH injector connector (E). VCM connector (F). Power steering pump oil pressure switch (G). LH exhaust camshaft OCV connector (A). LH/RH intake camshaft OCV connector (B). Oil pressure switch connector (C). Knock sensor connector (D). VPS connector (E). Condenser connector (F). Ground (G). Disconnect LH front oxygen sensor connector (A). Disconnect alternator connector (A). LH ignition coil connectors (A). LH injector connectors (B). VIS connector (C). LH intake CMPS connector (D). MAP sensor connector (A). PCSV connector (B). RH intake CMPS connector (A). Knock sensor connector (B). OTS connector (C). ETC connector (D). RH exhaust CMPS connector (E). WTS & gauge unit connector (A). LH exhaust CMPS connector (A). LH rear oxygen sensor connector (B). CKPS connector (C).
9. Disconnect the PCSV hose (A), fuel hose (B).
10. Drain the engine oil.
11. Remove the lower oil pan (A). Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan. Cut off applied sealer and remove the lower oil pan. 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 use the SST as a prybar. Hold the tool in position (on the gasket line) and tap in with a light hammer. Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
12. Install the jack to the edge of ladder frame (A) to support the engine. NOTE: Insert the rubber block between jack and ladder frame.
13. Disconnect the ground cable (A), and then remove the engine mounting bracket (B).
14. Remove the surge tank (A). (Refer to «INTAKE & EXHAUST SYSTEM»(ref-674573) ) NOTE: Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
15. Disconnect the RH ignition coil connectors (A) and the RH injector connectors (B).
16. Remove the LH/RH ignition coils (A).
17. Remove the exhaust OCV cap (A), and then remove the LH, RH cylinder head covers.
18. To release the tension, turn the drive belt tensioner counterclockwise then remove the drive belt (A).
19. Lift up the engine assembly by using the jack.
20. Remove the power steering pump (A). (Refer to POWER STEERING OIL PUMP .
21. Remove the air conditioner compressor (A). (Refer to «COMPRESSOR»(ref-674580-S25754434272014120300000) .
22. Remove the alternator (A).
23. Remove the drive belt idler (A).
24. Remove the drive belt auto tensioner (A).
25. Remove the water pump pulley (A).
26. Set No. 1 cylinder to TDC/compression. Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover. 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 clockwise one revolution (360°). NOTE: Do not rotate engine counterclockwise.
27. Remove the crankshaft pulley (A). 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. Install the SST (09231-3D100) to hold the ring gear after removing the dust cover. Remove the front muffler. (Refer to «INTAKE AND EXHAUST SYSTEM»(ref-674573) ) Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B). Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth. Fasten the two transaxle mounting bolts in the original mounted holes. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
28. Remove the water pump (A) and gasket (B).
29. Remove the timing chain cover (A). CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover. NOTE: 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.
30. Remove the oil pump chain cover (A).
31. Remove the oil pump chain tensioner assembly (A).
32. Remove the oil pump chain guide (A).
33. Install a set pin after compressing the RH timing chain tensioner.
34. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
35. Remove the RH timing chain guide (A) and RH timing chain (B).
36. Remove the oil pump chain sprocket (A) and oil pump chain (B).
37. Remove the crankshaft sprocket (A) (O/P & RH camshaft drive).
38. Install a set pin after compressing the LH timing chain tensioner.
39. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
40. Remove the LH timing chain guide (A) and LH timing chain (B).
41. Remove the crankshaft sprocket (A). (LH camshaft drive).
42. Remove the tensioner adapter assembly (A).

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