Thursday, February 24, 2011

The timing belt installation procedure for kia sedona 2003 year model?

Removal & Installation




  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Record the radio anti theft code data.
  3. Remove or disconnect the following:

    Negative battery cable
    Engine cover
    Accessory drive belts
    Idler pulley
    Crankshaft pulley
    Power steering pump pulley
    Belt tensioner pulley
    Upper and lower timing belt covers

  4. Support the engine with a floor jack and remove the engine mount.
  5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.

    Click image to see an enlarged view

    Fig. Timing belt routing and timing marks

  6. Remove or disconnect the following:

    Auto tensioner
    Timing belt

    Click image to see an enlarged view

    Fig. Timing belt and related components



To install:

  1. Ensure that the engine is set to Top Dead Center (TDC).
  2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
  3. Install the timing belt in the following order:
    1. Crankshaft sprocket
    2. Idler pulley
    3. Left bank exhaust camshaft sprocket
    4. Left bank intake camshaft sprocket
    5. Water pump pulley
    6. Right bank intake camshaft sprocket
    7. Right bank exhaust camshaft sprocket
    8. Tensioner pulley

  4. Install the auto tensioner. Do not remove the retaining pin at this time.
  5. Check that the crankshaft and camshaft timing marks are aligned correctly.
  6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
  7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
  8. Loosen the tensioner pulley center bolt.
  9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).

    Click image to see an enlarged view

    Fig. Adjusting the tensioner pulley

  10. Remove the auto tensioner retaining pin.
  11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
  12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.

    Click image to see an enlarged view

    Fig. Measuring the auto tensioner rod

  13. When the auto tensioner measurement is correct, install or connect the following:

    Engine mount
    Upper and lower timing belt covers
    Belt tensioner pulley
    Power steering pump pulley
    Crankshaft pulley
    Idler pulley
    Accessory drive belts
    Engine cover
    Negative battery cable



    -------------------------------------------
    Accessory Drive belt:---

    Accessory Belt Routing





    Click image to see an enlarged view

    Fig. Accessory serpentine belt routing-3.5L engine



    Click image to see an enlarged view

    Fig. Accessory serpentine belt routing-3.5L engine



    Click image to see an enlarged view

    Fig. Accessory serpentine belt (A) routing-3.8L engine

    Inspection



    Inspect the drive belt for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately.

    Removal & Installation



    1. Disconnect the negative battery cable.
    2. Rotate the auto tensioner clockwise to release tension, then remove the drive belt.

    To install:

    1. Install drive belt (A). Route the belt over the components in the following order: Crankshaft pulley - A/C pulley - idler pulley - generator pulley - water pump pulley - P/S pump pulley - tensioner pulley.
    2. Rotate auto tensioner arm in the counter-clockwise moving auto tensioner pulley bolt with wrench.
    3. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

      Click image to see an enlarged view

      Fig. Accessory serpentine belt routing-3.5L engine



      Click image to see an enlarged view

      Fig. Accessory serpentine belt (A) routing-3.8L engine





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      FOR TIMING CHAIN REMOVAL AND INSTALLATION:---

      Removal & Installation



      3.8L Engine
      1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
      2. Record the radio anti theft code data.
      3. Remove the engine from the vehicle.
      4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
      5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
      6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
      7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
      8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
      9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
      10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
      11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
        NOTE
        Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.

      12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
      13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
      14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
      15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
      16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.

        Click image to see an enlarged view

        Fig. Timing chain and related components-3.8L Engine


      To install:

      1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
      2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
      3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
      4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
      5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
      6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
      7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.

        Click image to see an enlarged view

        Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine

      8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
      9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
      10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
      11. Install the crankshaft sprocket, oil pump and right camshaft drive.
      12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
      13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
      14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.

        Click image to see an enlarged view

        Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine

      15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
      16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
      17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
      18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
      19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
      20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
      21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
      22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
        NOTE
        Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.



        Click image to see an enlarged view

        Fig. Sealant application (1 inch bead width)-3.8L Engine

      23. Apply sealant on the chain cover.
        NOTE
        The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.



        Click image to see an enlarged view

        Fig. Timing cover sealant application-3.8L Engine

      24. Install a new gasket to the timing case cover.
        NOTE
        It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.



        Click image to see an enlarged view

        Fig. Timing cover gasket installation (A) gaskets-3.8L Engine

      25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.

        Click image to see an enlarged view

        Fig. Timing cover bolt torque sequence and specification-3.8L Engine

      26. Install the timing case cover oil seal.
      27. Continue the installation in the reverse order of the removal procedure.

      Camshafts, Bearings, & Lifters

      REMOVAL & INSTALLATION

      Removal & Installation



      See the Rocker Arm Shaft Removal & Installation procedure.

      3.5L Engines
      1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
      2. Record the radio anti theft code data.
      3. Remove or disconnect the following:
        NOTE
        Keep all valvetrain components in order for assembly.



        Negative battery cable
        Engine cover
        Valve covers
        Accessory drive belts
        Idler pulley
        Crankshaft pulley
        Power steering pump pulley
        Belt tensioner pulley
        Upper and lower timing belt covers
        No. 3 engine mount
        Timing belt
        Camshaft sprockets



        Front bearing caps
        Rear bearing caps
        Center bearing caps
        Camshafts
        Rocker arms
        Hydraulic lifters


      To install:

      Click image to see an enlarged view

      Fig. Camshafts and related components-3.5L Engine



      Click image to see an enlarged view

      Fig. Camshaft installation alignment-3.5L Engine

      1. Set the No. 1 cylinder to Top Dead Center of the compression stroke.
      2. Install the lifters and rocker arms in their original positions.
      3. Install the camshafts aligned according to the illustration.
      4. Install the bearing caps. Tighten the bolts evenly in several passes to the following torque specifications:

        Front and rear bearing caps: 19-21 ft. lbs. (14-15 Nm)
        Center bearing caps: 88-106 inch lbs. (10-12 Nm)

      5. Install or connect the following:

        Camshaft sprockets. Tighten the bolts to 67-81 ft. lbs. (90-110 Nm).
        Timing belt
        No. 3 engine mount
        Upper and lower timing belt covers
        Belt tensioner pulley
        Power steering pump pulley
        Crankshaft pulley
        Idler pulley
        Accessory drive belts
        Valve covers. Tighten the bolts to 44-53 inch lbs. (5-6 Nm).
        Engine cover
        Negative battery cable

      6. Reprogram the anti theft codes.

      3.8L Engine
      1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
      2. Record the radio anti theft code data.
      3. Remove the engine from the vehicle.
      4. Remove the cam covers.
      5. Remove the timing chains.
      6. Remove the camshaft retaining bolts. Remove the camshafts.

        Click image to see an enlarged view

        Fig. Camshafts and related components-3.8L Engine


      To install:

      1. Apply a light coat of clean engine oil to the camshafts, prior to installation. Assemble the key groove of the camshaft rear side to the same level of head top surface.
      2. Ensure that the camshaft components are installed in the correct location and direction.
      3. Torque the camshaft bearing caps to specification and in the proper sequence.
      4. Continue the installation is the reverse of the removal procedure.

        Click image to see an enlarged view

        Fig. Camshaft bearing cap torque sequence-3.8L Engine



        Click image to see an enlarged view

        Fig. Camshaft bearing cap markings-3.8L Engine


        CYLINDER HEAD:----------

        Removal & Installation



        3.5L Engine
        1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
          NOTE
          Do not remove the cylinder head until the engine drops below normal operating temperature.

        2. Drain the cooling system.
        3. Relieve the fuel system pressure.
        4. Disconnect the negative battery cable.
        5. Remove the engine cover.
        6. Remove the timing belt.
        7. Remove the intake manifold.
        8. Remove the exhaust manifolds.
        9. Remove the cylinder head covers.
        10. Remove the camshafts.
        11. Remove the rocker arms and lash adjusters.
          NOTE
          Keep all valve train components in order for assembly.

        12. Remove the cylinder head bolts.
        13. Remove the cylinder heads.

          Click image to see an enlarged view

          Fig. Cylinder head exploded view-3.5L Engine


        To install:

        1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence to 78-85 ft. lbs. (105-115 Nm).
        2. Installation is the reverse of the removal procedure.

          Click image to see an enlarged view

          Fig. Cylinder head bolt torque sequence


        3.8L Engine
        1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
          NOTE
          Do not remove the cylinder head until the engine drops below normal operating temperature.

        2. Remove the engine from the vehicle.
        3. Remove the exhaust manifold retaining bolts. Remove the exhaust manifold.
        4. Remove the intake manifold retaining bolts. Remove the intake manifold.
        5. Remove the timing chain cover. Remove the timing chain.
        6. Remove the water temperature control assembly.
        7. Remove the camshaft covers. Remove the camshaft bearing cap. Remove the camshafts.
        8. Remove the cylinder head retaining bolts. Remove the cylinder head from the engine.
          NOTE
          Remove the cylinder head bolts in the reverse order of the cylinder head torque sequence and in several passes.


        To install:

        1. Install the cylinder heads using new gaskets. Be sure to use new cylinder head bolts.
        2. Sealant locations on the cylinder head and cylinder block must be free from contamination. Apply sealant part number TB1217H, as indicated.
          NOTE
          Apply sealant on the cylinder block top face before assembling the head gaskets. Apply sealant on the cylinder head gaskets after assembling the cylinder head gaskets on the cylinder block. The parts must be assembled within five minutes after the sealant was applied.



          Click image to see an enlarged view

          Fig. Sealant to engine block application-3.8L Engine



          Click image to see an enlarged view

          Fig. Sealant to cylinder head application-3.8L Engine



          Click image to see an enlarged view

          Fig. Sealant to engine block and cylinder head application-3.8L Engine

        3. Tighten the cylinder head bolts in sequence to specification.
        4. Continue the installation in the reverse order of the removal procedure.
        5. Check and adjust the valve clearance.

        -----------------
        ENGINE REMOVAL & INSTALLATION:---

        Removal & Installation



        3.5L Engine
        1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
        2. Drain the cooling system.
        3. Drain the transaxle fluid.
        4. Relieve the fuel system pressure.
        5. Remove the battery.
        6. Remove the engine cover.
        7. Remove the air cleaner assembly.
        8. Disconnect the engine wiring harness connectors.
        9. Disconnect the alternator wiring harness connectors.
        10. Disconnect the oil pressure switch connector.
        11. Disconnect the oil pressure sensor connector.
        12. Disconnect the starter motor wiring harness connectors.
        13. Disconnect the transaxle oil cooler hose.
        14. Remove the upper and lower radiator hoses.
        15. Remove the radiator.
        16. Remove the engine ground cable.
        17. Disconnect the brake booster vacuum hose.
        18. Disconnect the EVAP canister hose.
        19. Disconnect the fuel lines.
        20. Remove the heater hoses.
        21. Disconnect the throttle and cruise control cables.
        22. Disconnect the transaxle shift cable.
        23. Disconnect the power steering pump hose.
        24. Remove the oil pan shield.
        25. Remove the exhaust front pipe.
        26. Remove the outer tie rod ends.
        27. Remove the sway bar links.
        28. Remove the lower ball joints.
        29. Remove the axle halfshafts.
        30. Remove the intermediate shaft bolt.
        31. Remove the No. 3 and 4 engine mounts.
        32. Support the front subframe with a suitable powertrain jack.
        33. Remove the subframe bolts.
        34. Remove the impact bar bolts.
        35. Lower the powertrain and subframe away from the vehicle.

          Click image to see an enlarged view

          Fig. Engine mount locations and torque specifications-3.5L Engine



          Click image to see an enlarged view

          Fig. Front subframe bolt locations and torque specifications-3.5L Engine


        To install:

        1. Installation is the reverse of the removal procedure, while using the following torque values:

          Subframe bolts: 88-101 ft. lbs. (120-137 Nm)
          Impact bar bolts: 69-85 ft. lbs. (93-115 Nm)
          Engine mount bolts: 49-69 ft. lbs. (67-93 Nm)
          Engine mount through-bolts: 63-86 ft. lbs. (85-117 Nm)
          Tie rod ends: 51-58 ft. lbs. (69-79 Nm)


        3.8L Engine
        1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
        2. Remove the engine cover. Discharge the air conditioning system. Record the radio anti theft code data. Relieve the fuel system fuel pressure.
        3. Disconnect the negative battery terminal. Disconnect the positive battery terminal. Remove the battery from the vehicle.
        4. Remove the air intake hose and air cleaner assembly.
        5. Disconnect the MAF electrical connector. Disconnect the breather hose from the air cleaner hose. Remove the intake air hose and air cleaner assembly. Remove the battery tray.
        6. Remove the radiator grille upper cover. Disconnect the left and right oxygen sensor connectors.
        7. Drain the cooling system. Remove the upper and lower radiator hoses. Disconnect and plug the automatic transaxle fluid lines.
        8. Disconnect the high and low pressure pipes from the radiator and compressor.
        9. Disconnect the engine wiring harness. Remove the engine underhood fuse and relay box. Disconnect the FAM connectors.
        10. Unscrew the FAM mounting bolts and remove the FAM from the splash shield.
        11. Disconnect the transaxle wire harness connector and remove the transaxle control cable. Disconnect and remove the heater hoses.
        12. Remove the brake vacuum hose. Remove the upper power steering hose.
        13. Raise and support the vehicle safely. Remove the front tires and wheels.
        14. Remove the radiator grille upper cover, for convenience.
        15. Disconnect the power steering return hose. Remove the radiator support upper member, for convenience.
          NOTE
          The bottom side bolt, which can be seen after removing the under cover, should be loosened for removal of the radiator support upper member assembly.

        16. Remove the under cover. Drain the engine oil. Remove the front exhaust pipe.
        17. Disconnect the wheel speed sensor. Disconnect the stabilizer bar link.
        18. Remove the brake caliper assemblies. Wire them to the side to prevent damage to the brake hoses.
        19. Properly support the engine and transaxle assembly using the proper engine/transaxle support tool.
        20. Remove the engine mounting bolt. Remove the transaxle insulator mounting bolt.
        21. Support the engine and transaxle assembly with a jack. Remove the sub frame with the engine and transaxle assembly.

        To install:

        1. Installation is the reverse of the removal procedure.
        2. Adjust the shift cable. Fill the engine and transaxle to specification with the proper fluids.
        3. Before starting the engine turn the ignition switch to the RUN position so that the fuel pump runs for approximately two seconds and the fuel line pressurizes.
        4. Reprogram the radio anti theft code data.
        5. Repeat the operation two or three more times, than check for fuel leakage.