Broken Timing Belt

[bruno1926]

I have suffered a broken cam belt on my 2.9 TDI Sedona. I guess I was lucky as I was just starting it. On inspection it broke 6 rocker arms and the 1st 3 cylinders.After taking the head off and checking the valves the appear not to be bent or at least in spec.Question is in years gone by the rocker arms would have been made from steel rather than Aluminum as these were. These breaking appear to have saved the engine from further damage .So I'm now in the process of putting it all back together. Heres a thing on mine a MK1 you cannot get the rocker cover off with out removing the injectors as the return from the injectors hits the ledge on the bottom of the rocker cover and there is just no way to get it off without taking the injectors out which took 4.5 hours .Rather than but an expensive removal tool I got a nut that fitted the injector and welded it to a large slide hammer and did it like that but it can be awful hard to remove them .I have a workshop manual for the 2.9 CRDI engine although its not from Kia but a different manufacturer,but is quite useful for bothe the common rai and the earlier TDI engine.

[Crevit]

Hi there how did you remove the Cylinder Head? My car suffered a major breakdown with the timing belt mechanism sheered off the cam shaft.. my father is fixing it for me and has removed all the intake manifold fixings, the exhaust manifold and all head bolts.. its loose but still won't come off? Any ideas?

[bruno1926]

Has he removed ALL the bolts? some are hidden in recesses in the head.Have you took the long bolt out of the alternator?Have you removed the brackets on the back of the head that hods 1 or 2 pipes on?It maybe just stuck on the gasket try putting a bar under the overhang on one side and gently bar it up.