How to Replace Timing Belt - Kia Forum
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post #1 of 2 (permalink) Old 08-25-2006, 02:06 AM Thread Starter
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How to Replace Timing Belt (2006 to 2009) DOHC

Removal for 1.6L engines : ONLY 2006 to 2009 CARS


Engine removal is not required for this procedure.

1.Remove the engine cover.

2.Remove the RH front wheel.

3.Remove the 2 bolts and RH side cover.

4.Temporarily loosen the water pump pulley bolts.

5.Remove the alternator drive belt

6.Remove the air conditioner compressor drive belt

7.Remove the power steering pump drive belt

8.Remove the 4 bolts and water pump pulley.

9.Remove the 4 bolts and timing belt upper cover

10.Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that the timing mark of camshaft sprocket is aligned with the timing mark of cylinder head cover. (No.1 cylinder compression TDC position)

11.Remove the crankshaft pulley bolt and crankshaft pulley

12.Remove the crankshaft flange

13.Remove the 4 bolts and timing belt lower cover

14.Remove the timing belt tensioner and timing belt.

15.Remove the bolt and timing belt idler

16.Remove the crankshaft sprocket

17.Remove the cylinder head cover.

(1)Remove the wire harness bracket

(2)Remove the ignition coil.

(3)Remove the PCV (Positive Crankcase Ventilation) hose and the breather hose from the cylinder head cover

(4)Remove the engine cover bracket

(5)Loosen the cylinder head cover bolts and then remove the cover and gasket.

18.Remove the camshaft sprocket.

Hold the portion of the camshaft with a hexagonal wrench, and remove the bolt with a wrench and remove the camshaft sprocket.

INSTALLATION:

1.Install the camshaft sprocket and tighten the bolt to the specified torque.

(1)Temporarily install the camshaft sprocket bolt

(2)Hold the portion of the camshaft with a hexagonal wrench, and tighten the bolt with a wrench
Tightening torque :78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)



2.Install the cylinder head cover.

(1)Install the cylinder head cover and bolts
Tightening torque :7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

(2)Install the engine cover bracket

(3)Install the PCV(Positive Crankcase Ventilation) hose and breather hose to the cylinder head cover.

(4)Install the ignition coil.

3.Install the crankshaft sprocket

4.Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston placed at top dead center and its compression stroke.

5.Install the idler pulley and tighten the bolt to the specified torque.

Tightening torque :42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)

6.Temporarily install the timing belt tensioner

7.Install the belt so as not give slack at each center of shaft. Use the following order when installing timing belt.
Crankshaft sprocket →idler pulley →camshaft sprocket →timing belt tensioner

8.Adjust the timing belt tension.

(1)Loosen the tensioner pulley mounting bolt and apply tension to the timing belt.

(2)After checking the alignment between each sprocket and each timing belt tooth, tighten the mounting bolt and one by one.

Tightening torque :19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

(3)Then recheck the belt tension.
Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (11lb)], the timing belt cog end is aprox. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center.

4)Timing belt tension measuring procedure
(by a sonic tension guage)
Rotate crankshaft in clockwise direction to set 1st piston on top dead center (TDC) and rotate crankshaft in counterclockwise to 90 then measure the belt tension in the middle of tension side span (in arrow direction of above illustration) by free vibration method.


9.Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.


10.Install the timing belt lower cover with 5bolts

Tightening torque :7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

11.Install the flange and crankshaft pulley, and then tighten crankshaft pulley bolt. Make sure that crankshaft sprocket pin fits the small hole in the pulley.

Tightening torque :137.3 ~ 147.1N.m (14.0 ~ 15.0kgf.m, 101.3 ~ 108.5lb-ft)

12.Install the timing belt upper cover with 4 bolts.

Tightening torque :7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

13.Install the water pump pulley and 4 bolts.

14.Install the power steering pump drive belt

15.Install the air conditioner compressor drive belt

16.Install the alternator drive belt

17.Install the RH side cover with 2 bolts

18.Install the RH front wheel.


Tightening torque :88.3 ~ 98.1N.m (9.0 ~ 10.0kgf.m, 65.1 ~ 72.3lb-ft)

19.Install the engine cover with bolts.


Tightening torque :3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

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Last edited by Raven1210; 04-11-2009 at 03:10 AM.
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post #2 of 2 (permalink) Old 05-27-2009, 12:16 AM
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Also see this thread.

DIY Replace Timing Belt - WARNING Int. Engine - Interval
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Last edited by ron1004; 05-27-2009 at 12:19 AM.
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