Kia Optima: Removal
| • |
Use fender covers to
avoid damaging painted surfaces. |
| • |
To avoid damage, unplug
the wiring connectors carefully while holding the connector portion.
|
|
|
Mark all wiring and hoses to avoid misconnection. |
|
In case of removing the high pressure fuel pump, high pressure fuel pipe,
delivery pipe, and injector, there may be injury caused by leakage of the
high pressure fuel. So don’t do any repair work right after engine stops. |
| 1. |
Remove the engine cover. |
| 2. |
Disconnect the battery negative
terminal (A). |
| 3. |
Remove the air duct (B).
|
| 4. |
Remove the air cleaner assembly.
| (1) |
Disconnect the breather
hose (A), the recirculation hose (B) and the brake booster vacuum
hose (C). |
| (2) |
Disconnect the air intake
hose (D) and then remove the air cleaner assembly (E). |
|
| 5. |
Remove the intercooler inlet
hose (A).
|
| 6. |
Disconnect the recirculation
valve connector (A) and the vacuum hose (B), and then remove the intercooner
inlet pipe & hose assembly (C)
|
| 7. |
Remove the RH front wheel. |
| 8. |
Remove the under covers (A,B).
|
When removing the under cover (B), unfasten the mounting bracket
bolts and then remove the under cover and mounting bracket assembly. |
|
| 9. |
Turn the crankshaft pulley and
align its groove with the timing mark of the timing chain cover to set the
piston of No.1 cylinder to the top dead center on compression stroke.
|
| 10. |
Disconnect the exhaust OCV (Oil
control valve) connector (A) and the oxygen sensor connector (B).
|
| 11. |
Disconnect the ignition coil
connectors (A) and the fuel pump connector (B), then remove the wiring protector.
|
| 12. |
Remove the ignition coils (A).
|
| 13. |
Disconnect the fuel hose (A)
and PCSV (Purge control solenoid valve) hose (B).
|
| 14. |
Disconnect PCSV (Purge control
solenoid valve) connector (A) and loosen the vacuum pipe assembly mounting
bolts and nut.
|
| 15. |
Remove the high pressure pipe
(A). (Refer to FL group)
|
| 16. |
Remove the high pressure fuel
pump (A) and the roller tappet (B). (Refer to FL group)
|
| 17. |
Disconnect the PCV (Positive
crankcase ventilation) hose (A) and tnen remove the front engine hanger
(B).
|
| 18. |
Remove the cylinder head cover
(A).
|
| 19. |
Remove the drive belt (A) after
turning the drive belt tensioner (B) counterclockwise.
|
| 20. |
Remove the A/C compressor lower
bolts (A).
|
| 21. |
Remove the A/C compressor bracket
(A).
|
| 22. |
Drain the engine oil. |
| 24. |
Set the jack to the edge of ladder
frame.
|
Put the wooden block between ladder frame and jack. |
|
Be careful not to damage the balance shaft & oil pump module. |
|
| 25. |
Disconnect the ground line (A),
and then remove the engine mounting support bracket (B).
|
| 26. |
Remove the idler (A), the water
pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner
pulley (D).
|
Tensioner pulley bolt is left-handed screw. |
|
Use the SST (Ring gear stopper, 09231-3K000) (A) to remove the crankshaft
pulley bolt, after removing the starter. |
|
| 27. |
Remove the drive belt tensioner
(A).
|
| 28. |
Remove the engine support bracket
(A).
|
| 29. |
Remove the timing chain cover
(A) by gently prying the portions between the cylinder head and cylinder
block.
|
Be careful not to damage the contact surfaces of cylinder block,
cylinder head and timing chain cover. |
|
| 30. |
Make sure that the key (A) of
crankshaft is aligned with the mating surface of main bearing cap. As a
result of this, the piston of No.1 cylinder is placed at the top dead center
on compression stroke.
|
| 31. |
Release the ratchet by pulling
the link down using a thin rod. Compress the piston and then insert a stopper
pin (A) into the hole on the ratchet to hold the compressed piston. Remove
the timing chain tensioner (B).
|
| 32. |
Remove the timing chain tensioner
arm (A).
|
| 33. |
Remove the timing chain (A).
|
| 34. |
Remove the timing chain guide
(A).
|
| 35. |
Remove the timing chain oil jet
(A) and the crankshaft chain sprocket (B).
|
| 36. |
Remove the balance shaft chain.
(Refer to Lubrication system in this group) |
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1.
Check the camshaft sprocket and
crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
...
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arrow. 
arrow around more than 2/3 edge
of the oil pan, remove it from the ladder frame. 
Inspection