Timing System - Hev: Removal & Installation Kia Optima III

Removal

Note. Mark all wiring and hoses to avoid misconnection.

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1. Shut off the high voltage circuit. (Refer to «HIGH VOLTAGE SHUTOFF PROCEDURE»(ref-535735-S00077355672013031200000) .
2. Remove the engine cover.
3. Remove the air cleaner assembly. (Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-535712-S00181035742013031200000) in this group)
4. Remove the RH front wheel. (Refer to «FRONT WHEEL ALIGNMENT»(ref-535718-S01048776032013031200000) )
5. Remove the under cover. (Refer to «ENGINE AND TRANSAXLE ASSEMBLY»(ref-535712-S00181035742013031200000) in this group)
6. 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.
7. Disconnect the exhaust OCV (Oil control valve) connector (A) and then remove the wiring from the cylinder head cover.
8. Disconnect the PCV (Positive crankcase ventilation) hose (A).
9. Disconnect the ignition coil connectors (A) and then remove the wiring protector (B).
10. Remove the ignition coils (A).
11. Remove the cylinder head cover (A).
12. Remove the water pump drive belt (A). Put the SST (09252-3D100) between the crankshaft pulley and the drive belt. Rotate the crankshaft pulley clockwise. Then the drive belt is removed.
13. Remove the drive belt. Insert a stopper pin (B) on the drive belt #1 tensioner after rotating the arm (A) counterclockwise. Remove the drive belt (D) after rotating the drive belt #2 tensioner arm (C) clockwise.
14. Remove one side bolt (A) and two lower bolts (B) on the A/C compressor.
15. Remove the A/C compressor bracket (A).
16. Drain the engine oil.
17. 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. NOTE: Loosen one oil pan bolt near each corner of the oil pan leaving the bolts held in by about 2 threads. Then remove all other pan bolts. NOTE: Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of $$1 arrow. After tapping the SST with a plastic hammer along the direction of #2 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.
18. 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.
19. Disconnect the ground line (A), and then remove the engine mounting support bracket (B).
20. Remove the crankshaft pulley (A) and the idler (B).
21. Remove the water pump pulley (A) and the dust cover (B).
22. Remove the engine support bracket (A).
23. Remove the timing chain cover (A) by gently prying the portions between the cylinder head and cylinder block. CAUTION: Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
24. Make sure that the key 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.
25. Release the ratchet 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).
26. Remove the timing chain tensioner arm (A).
27. Remove the timing chain (B).
28. Remove the timing chain guide (A).
29. Remove the timing chain oil jet (A) and the crankshaft chain sprocket (B).
30. Remove the balance shaft chain.