Kia Sorento: Timing Chain Cover Repair procedures
This working procedure does not require engine removal.
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In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, andinjector, there
may be injury caused by leakage of the high pressure fuel. So don’t do any repairwork right after engine
stops.
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Use fender covers to avoid damaging painted surfaces.
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To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
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Remove the variable force solenoid valve (VFS) and E-CVVT cover first when removing the timing
chain cover.
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Mark all wiring and hoses to avoid misconnection.
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| 1. |
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel
Line")
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| 2. |
Disconnect the battery negative ( - ) terminal.
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| 3. |
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
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| 4. |
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under
Cover")
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| 5. |
Drain the engine oil.
(Refer to Lubrication System - "Engine Oil")
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| 6. |
Remove the drive belt and water pump belt.
(Refer to Drive Belt System - "Drive Belt")
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| 7. |
Remove the crankshaft damper pulley.
(Refer to Drive Belt System - "Crankshaft Damper Pulley")
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| 8. |
Remove the drive belt tensioner.
(Refer to Drive Belt System - "Drive Belt Tensioner")
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| 9. |
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
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| 10. |
Remove the oil level gauge.
(Refer to Lubrication system - "Oil level gauge &
pipe")
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| 11. |
Remove the A/C compressor mounting bolts.
(Refer to Heating, Ventilation and Air Conditioning System -
"Compressor")
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| 12. |
Remove the A/C compressor mounting bracket (A).
Tightening torque :
19.6 - 23.5 N·m (2.0 - 2.4 kgf·m , 14.4 - 17.3 lb·ft)
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| 13. |
Remove the oil pan.
(Refer to Lubrication System - "Oil Pan")
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| 14. |
Install the jack to the edge of ladder frame.
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Put the rubber block between the jack and lower crankcase to avoid damaging the lower
crankcase.
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Be careful not to damage the balance shaft and oil pump.
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| 15. |
Remove the engine mounting support bracket and the engine mounting bracket.
(Refer to Engine and Transaxle Assembly System - "Engine
Mounting")
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| 16. |
Disconnect the engine ground cable (A).
Tightening torque :
10.7 - 13.7 N·m (1.1 - 1.4 kgf·m , 7.9 - 10.1 lb·ft)
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| 17. |
Remove the engine support bracket (A).
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| 18. |
Remove the E-CVVT cover (A).
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Be careful not to apply external force to the brush after removing the cover.
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| 19. |
Remove the variable force solenoid valve (VFS) (A).
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When removing the timing chain cover, be sure to remove the variable force solenoid valve (VFS)
first.
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| 20. |
Remove the timing chain cover (A).
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When removing the timing chain cover, be careful not to damage the contact surfaces of cylinder
block, cylinder head and lower crankcase.
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| 1. |
Check if the oil flows inside the E-CVVT cover.
If the oil flows inside the E-CVVT cover, replace the E-CVVT cover
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| 2. |
Check the connector brush wear condition.
If the brush is worn down, replace the E-CVVT cover.
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| 1. |
Install the timing chain cover.
| (1)
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Make sure to remove the hardening sealant, foreign materials, oil, dust and moisturegathered in the
liquid gasket sealing surface (cam carrier, cylinder head, cylinder block, lower crankcase). Then,
spray the cleaner on the sealing surface and wipe off with a clean towel.
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| (2)
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Apply a sealant for liquid gasket to the interface between the cam carrier, cylinder head,cylinder
block and lower crankcase.
Bead width : 3.0 - 5.0 mm (0.11 - 0.19 in.)
Sealant : THREEBOND 1217H / LOCTITE 5900H or
equivalent
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| (3)
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The part must be assembled within 5 minutes after sealant was applied on the mounting surface of
liquid gasket of timing chain cover.
Bead width : 3.0 - 5.0 mm (0.11 - 0.19 in.)
Sealant : THREEBOND 1217H / LOCTITE 5900H or
equivalent
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The dowel pins on the cylinder block and holes on the timing chain cover should be used asa
reference in order to assemble the timing chain cover (A) to be in exact position.
Tightening torque :
Bolt B : 9.8 - 11.7 N·m (1.0 - 1.2 kgf·m , 7.2 - 8.6 lb·ft)
Bolt C : 18.6 - 22.5 N·m (1.9 - 2.3 kgf·m , 13.7 - 16.6 lb·ft)
Bolt D : 9.8 - 11.7 N·m (1.0 - 1.2 kgf·m , 7.2 - 8.6 lb·ft)
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The engine starting or pressure tests should not be performed within 30 minutes
after the timing chain cover was assembled.
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Always install the timing chain cover mounting bolt (D) with a new one.
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| 2. |
Replace the front oil seal if neccesary.
(Refer to Timing System - "Front oil Seal")
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| 3. |
Remove it by breaking the center of E-CVVT motor plug (A).
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Remove after 30 minutes of switching "OFF" the ignition to drain out the oil
inside the E-CVVT motor plug.
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Do not tilt the front of engine (timing chain cover side) downward as residual oil may flow
outduring E-CVVT motor plug removal.
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If oil flows out during E-CVVT motor plug removal, wipe off immediately and block the
motorshaft inlet with a clean towel.
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| 4. |
Clean the E-CVVT motor plug mounting surface (A) with oil cleaner.
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If the surface is not cleaned, E-CVVT motor plug may be separated due to diminished
separation force from residual oil.
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When spraying oil cleaner, block around the motor shaft inlet and rotor gap with a clean
towel to prevent inflow of oil from flowing into the rotor gap.
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| 5. |
When reusing the E-CVVT cover, inspect the below items.
| (1)
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If there is sign of leakage from inside the E-CVVT cover, replace it with a new one.
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| (2)
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Check the connector brush wear condition.
Specification : More than 5 mm (0.1969 in.)
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If measurement is below specification, replace the E-CVVT cover with a new one.
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Check for damaged oil seal (A) and replace any damaged E-CVVT cover with a new one.
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After inspecting E-CVVT, if no problem is found, replace the o-ring (A) with a new one.
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| 6. |
Install the E-CVVT cover.
| (1)
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Apply engine oil to the oil seal lip (A).
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When applying oil, keep the connector brush (A) clean from foreign materials.
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Insert the SST(09243 - C2000) into the E-CVVT motor shaft.
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Correctly mount SST on to the motor shaft.
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Slowly push the E-CVVT cover (A) until it is flushed with the timing chain cover surface.
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Installing the E-CVVT cover without SST may cause oil leakage inside the E-CVVT motor due
to damaged or separated E-CVVT oil seal.
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| (4)
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Pre-tighten the bolts in the below sequence, and then remove the SST (09243 - C2000).
Tightening torque :
0.9 - 1.9 N·m (0.1 - 0.2 kgf·m , 0.7 - 1.4 lb·ft, 8.7 - 17.4 lb·in)
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| (5)
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Tighten the bolts to the specified torque in the sequence below.
Tightening torque :
9.8 - 11.7 N·m (1.0 - 1.2 kgf·m , 7.2 - 8.6 lb·ft)
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| 7. |
Install the E-CVVT plug.
| (1)
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Insert the plug into the E-CVVT cover hole using SST (09243 - C2000).
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Mount the stopper of SST (09243 - C2000) so that it sits at the end of E-CVVT motor shaft.
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| 8. |
Inspect the pressed depth of E-CVVT plug.
| (1)
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By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of motor
shaft (  ).
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By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of E-CVVT
plug (  ).
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| (3)
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Calculate the pressed depth (  )
of motor plug. If out of specification, reinstall after replacing the E-CVVT plug with a new one.
Specification : 1.1 - 2.1 mm (0.0433 - 0.0826 in.)
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| 9. |
Insert the E-CVVT cover plug so that the protrusion reach to E-CVVT cover groove correctly.
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Check how much protrude after installing the E-CVVT plug.
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Be careful that the plug is not inserted inside E-CVVT cover beyond the regulated range.
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| 10. |
Install the variable force solenoid valve(VFS) (A).
Tightening torque :
9.8 - 11.7 N·m (1.0 - 1.2 kgf·m , 7.2 - 8.6 lb·ft)
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Do not reuse the variable force solenoid valve (VFS) if it is dropped.
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When installing the variable force Solenoid valve (VFS), pay attention to the following
points.
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| 1) |
After replacing the variable force Solenoid valve (VSF) O-ring (A) with a new one, apply
engine oil to the new O-ring (A).
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Push the variable force solenoid valve (VFS) to the end of the timing chain cover
mountingsurface, and then pre-tighten the bolts.
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Tighten the variable force solenoid valve (VFS) with specified torque.
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| 11. |
Install the engine support bracket (A).
Tightening torque :
96.1 - 114.7 N·m (4.0 - 4.5 kgf·m , 70.8 - 84.6 lb·ft)
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Pre-tighten the bolts in the order of 1→2→3
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| (2)
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Turn the bracket counterclockwise and install the bolt 1.
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| (3)
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Install in order of 2 → 3 → 4 → 5 →6 .
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| 12. |
Install in the reverse order of removal.
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Replacement
1.
Remove the crankshaft damper pulley.
(Refer to Drive Belt System - "Crankshaft Damper Pulley")
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Removal
1.
Release the residual pressure in fuel line.
(Refer to Fuel Delivery System - "Release Residual Pressure in Fuel
Li...
Front Oil Seal Repair procedures
Timing Chain Repair procedures
