DIY Timing Belt - WARNING Interference Engine - Service Interval - Kia Forum
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post #1 of 94 (permalink) Old 08-25-2006, 02:58 AM Thread Starter
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Default DIY Timing Belt - WARNING Interference Engine - Service Interval

Removal for 1.6L engines :


REMOVAL 1. Disconnect negative battery cable.
2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air conditioning(A/C) compressor drive belt.
3. Remove P/S and/or A/C drive belt.
4. Loosen generator mounting bolts and adjusting bolt.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark ontiming belt pulley is aligned with timing mark on engine.
10. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.


Do not move camshaft or crankshaft once timing marks have been correctly positioned.
11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
13. Remove tensioner pulley.
14. Remove timing belt.


Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation.
INSTALLATION 1. Install tensioner pulley.


Replace tensioner spring whenever timing belt is replaced.
2. Pull tensioner pulley to its furthest point and tighten lock bolt.
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
4. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.


If existing timing belt is being reused install belt in proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley, and tensioner pulley in that order.
6. Check that there is no looseness in the belt between idler pulley and exhaust camshaft pulley or between intake and exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.


Do not add additional tension.
8. Tighten tensioner pulley lock bolt to specified torque.
Tightening torque:28~38 lb-ft (38~51 Nm, 3.9~5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing mark on engine block.
10. Check that "I" mark on intake camshaft pulley and "E" mark on exhaust camshaft pulley are aligned with marks on seal plate.
11. If they are not aligned, remove timing belt and start process from tensioner&;nbsp;installation.
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys If deflection is not correct, repeat from tensioner installation.
Deflection pressure:22 Ib. (98 N, 10 kg)Deflection:0.39~0.50 in. (11~13 mm)
13. Install lower and upper timing belt covers in that order.
Tightening torque:5.8~8.0 Ib-ft (7.9~10.7 Nm, 0.8~1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 Nm, 1.3~1.8 kg-m)
15. Install water pump pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 Nm, 1.3~1.8 kg-m)
16. Install generator belt and adjust the tension.


17. Install P/S and/or A/C drive belt and adjust the tension.
18. Connect negative battery cable.
INSPECTION

Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt.
1. Replace timing belt if it is contaminated with oil or grease.
2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as necessary.


3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.


5. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.




Replace any component that shows damage, excessive wear, or that appears prone to a possible failure


Removal for 1.5L engines :

1.Disconnect negative battery cable.
2.Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air conditioning (A/C) compressor drive belt.

http://msw.kiausa.com/data/PASSENGER...G/lc3b600a.gif

3.Remove P/S and/or A/C drive belt.
4.Loosen generator mounting bolts and adjusting bolt.
5.Remove generator bolts.
6.Remove water pump pulley.
7.Remove crankshaft pulley.
8.Remove upper and lower timing belt covers.
9.Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
10.Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.

http://msw.kiausa.com/data/PASSENGER...G/lc3b600b.gif

11.Loosen tensioner pulley lock bolt.
12.Protect timing belt with a rag.
13.Remove tensioner pulley.
14.Remove timing belt.

Install :

1.Install tensioner pulley
2.Pull tensioner pulley to its furthest point and tighten lock bolt.

http://msw.kiausa.com/data/PASSENGER...G/lc3b620a.gif
3.Check that timing mark on timing belt pulley is aligned with timing mark on engine

4.Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.

http://msw.kiausa.com/data/PASSENGER...G/lc3b620b.gif

5.Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley, and tensioner pulley in that order.
6.Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and exhaust camshaft pulleys.
7.Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.
8.Tighten tensioner pulley lock bolt to specified torque.
Tightening torque:28~38 lb-ft (38~51 Nm, 3.9~5.2 kg-m)
9.Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing mark on engine block.
10.Check that "I" mark on intake camshaft pulley and "E" mark on exhaust camshaft pulley are aligned with marks on seal plate.
11.If they are not aligned, remove timing belt and start process from tensioner installation.
12.Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is not correct, repeat from tensioner installation
Deflection pressure:22 Ib. (98 N, 10 kg)Deflection:0.39~0.50 in. (11~13 mm)
13.Install lower and upper timing belt covers in that order.
Tightening torque:5.8~8.0 Ib-ft (7.9~10.7 Nm, 0.8~1.1 kg-m)
14.Install timing belt guide plate and crankshaft pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 Nm, 1.3~1.8 kg-m)
15.Install water pump pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 Nm, 1.3~1.8 kg-m)

http://msw.kiausa.com/data/PASSENGER...G/lc3b600a.gif

16.Install generator belt and adjust the tension.

17.Install P/S and/or A/C drive belt and adjust the tension.
18.Connect negative battery cable.

[/SIZE]

Last edited by Raven1210; 01-16-2009 at 02:08 AM.
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post #2 of 94 (permalink) Old 10-09-2006, 08:45 AM
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Default Timing Belt question

My father in law is replacing my timing belt and he is needing I believe he said the print out so he can get the timing right. Is that information in what you posted, I know nothing about cars. Thanks
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post #3 of 94 (permalink) Old 10-09-2006, 08:33 PM Thread Starter
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all this is right it came from a kia repair site. for the techs
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post #4 of 94 (permalink) Old 10-09-2006, 11:31 PM
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Quote:
Originally Posted by andydye25801
My father in law is replacing my timing belt and he is needing I believe he said the print out so he can get the timing right. Is that information in what you posted, I know nothing about cars. Thanks
Go to the links posted by Raven1210 and you will find the needed pictures with description which can be printed for your father in law.

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Last edited by ron1004; 10-09-2006 at 11:33 PM.
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post #5 of 94 (permalink) Old 02-27-2009, 11:34 PM
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Default timing belt as bad as it gets

IMG]http://i399.photobucket.com/albums/pp80/tinman19672009/dscn4528.jpg[/IMG]


This is my 2002 rio after it blew a timing belt.
I don't think there is any doubt that it is a interfering engine

2002 Kia Rio
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post #6 of 94 (permalink) Old 02-27-2009, 11:46 PM
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Ouch !

Amazing pictures.
Must have been at speed when the belt went.

Was the belt replacement overdue, or was it premature failure?

Quality and not quantity counts.

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post #7 of 94 (permalink) Old 02-28-2009, 12:48 AM
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It was over due, it had 77K on it. It was my fault, was going about 40 when it just quit. Coasted to a stop with the clutch out so the motor was still turning.
I never heard of the word "interference engine " before this, now I know better.
I'm just amazed that someone would design a engine that the whole survival depends on a darn belt!!!!!!!......If this was the sixty's and you were a engineer designing cars you would been laugh at if you came up this junk.
Anyway I got a used motor from a junk yard. When I called the guy said come on down and you can start it and here it run its still in the car. when I got there it was the same exact car, even color, it was just wrecked in the rear. I started it and it ran fine, no noises and very responsive when you stepped on the gas.
Before i put in the car needless to say i changed the timing belt, what was odd was when I lined up the timing marks before I removed the belt the exhaust cam spocket was off 1 tooth, I couldn't believe it, i even rotated the motor a number of times and it was off..........I was surprised it ran so good when i started it at the junk yard. I'll bet if I could have driven it it would have been real sluggish. I don't believe it was the original belt, I can just hear the previous owner of that car saying "you know ever since I had that timing belt changed the car has never run right" lol
Its in the car now and running fine. (I also changed the tensioner, idler and water pump)
tinman

2002 Kia Rio

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post #8 of 94 (permalink) Old 02-28-2009, 09:08 AM
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Glad everything worked out for you in the end. There many mfg. using this type of engine.
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post #9 of 94 (permalink) Old 03-01-2009, 12:11 AM
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wow it's like deja vu all over again...and again, and again, and again... lol. you're going to go through the steps like we all have (timing belt breakers)... it is what it is... i can't believe it did that kind of damage at 40mph... we were going 35-40 and only had a couple of little holes in pistons and there were valves stuck in the holes.. just had dents in the others from all the other valves breaking off. i bet your belt broke completely as opposed to only a few teeth breaking off as is more typical. to say the least you are probably for certain going to have to go back with oversized pistons on those cylinders... i'd upgrade that orange fram too.. lol
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post #10 of 94 (permalink) Old 03-03-2009, 08:20 AM
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i just threw up in my mouth upon seeing what happened,i was coming off the exit and the car just died.....nothing....i had it towed home and changed the timing belt it took me 9hrs yuck!! i started the car and it sounds like its on 3 cyl. im afraid to do a compression test....what are the chances i need a new motor??? i love my kia im just dreading the worst!!!

thanks
fabio
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