Kia Sportage: Timing System / Timing Chain Cover Repair procedures

Kia Sportage QL (2015-2019) Service Manual / Engine Mechanical System / Timing System / Timing Chain Cover Repair procedures

Removal
  
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.
  
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.
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
3.
Remove the air duct.
4.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
5.
Remove the drive belt.
(Refer to Timing System - "Drive Belt")
6.
Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "Cylinder Head Cover")
7.
Remove the oil pan.
(Refer to Lubrication System - "Oil Pan")
8.
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.
9.
Disconnect the ground cable, and then remove the engine mounting support bracket.
(Refer to Engine and Transaxle Assembly - "Engine Mounting")
10.
Remove the engine support bracket (A).

11.
Remove the E-CVVT cover (A).

  
Be careful not to apply the force on the connector brush after removing the E-CVVT cover.
12.
Remove the drive belt tensioner.
(Refer to Timing System - "Drive Belt Tensioner")
13.
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.
Inspection
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.
2.
Check the connector brush wear condition.
If the brush is worn down, replace the E-CVVT cover assembly.
Installation
1.
Install the timing chain cover.
(1)
Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2)
The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and etc.
(3)
Before assembling the timing chain cover, liquid sealant Loctite 5900H or equivalent should be applied on the gap between camshaft front bearing cap, cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.
Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in.)

(4)
After applying liquid sealant Loctite 5900H or equivalent on the timing chain cover.
The part must be assembled within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path of oil leakage.
Bead width : 2.0 - 3.0 mm (0.08 - 0.12 in.)

(5)
The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
Tightening torque
M6 X 25 bolt :
7.8 - 9.8 N·m (0.8 - 1.0 kgf·m, 5.8 - 7.2 lb·ft)
M8 X 28 bolt :
18.6 - 22.6 N·m (1.9 - 2.3 kgf·m, 13.7 - 16.6 lb·ft)

  
The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.
2.
Install the front oil seal.
(Refer to Timing System - "Front Oil Seal")
3.
Install the drive belt tensioner.
(Refer to Timing System - "Drive Belt Tensioner")
4.
Remove it by breaking the center of E-CVVT motor plug (A).

  
Remove after 30 minutes of switching "OFF" the ignition to drain out the oil inside the E-CVVT motor plug.
Do not tilt the front of engine (timing chain cover side) downward as residual oil may flow out during E-CVVT motor plug removal.
If oil flows out during E-CVVT motor plug removal, wipe off immediately and block the motor shaft inlet with a clean towel.
5.
Clean the E-CVVT motor plug mounting surface (A) with oil cleaner.

  
If the surface is not cleaned, E-CVVT motor plug may be separated due to diminished separation force from residual oil.
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.
6.
When reusing the E-CVVT cover, inspect the below items.
(1)
If there is sign of leakage from inside the E-CVVT cover, replace it with a new one.
(2)
Check for worn connector brush.
Specification : Over 5 mm (0.1969 in.)

If measurement is below specification, replace the E-CVVT cover with a new one.
(3)
Check for damaged oil seal (A) and replace any damaged E-CVVT cover with a new one.

(4)
After inspecting E-CVVT, if no problem is found, replace the o-ring (A) with a new one.

7.
Install the E-CVVT cover.
(1)
Apply engine oil on oil seal lip (A).

  
When applying oil, keep the connector brush (A) clean from foreign materials.

(2)
Insert SST (09243-C2000) into the E-CVVT motor shaft.

  
Correctly mount SST onto the motor shaft.
(3)
Slowly push the E-CVVT cover (A) until it is flush with the timing chain cover surface.

  
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.
(4)
Pre-tighten the bolts in the below sequence, and then remove the SST (09243-C2000).
Tightening torque :
1.0 - 2.0 N·m (0.1 - 0.2 kgf·m, 0.7 - 1.4 lb·ft)

(5)
Tighten the bolts to the specified torque in the sequence below.
Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

8.
Install the E-CVVT plug.
(1)
By using SST (09243-C2000), insert the plug (A) into the E-CVVT cover hole.

  
Do not reuse a E-CVVT motor plug.
(2)
Mount the stopper of SST so that it sits at the end of E-CVVT motor shaft.

9.
Inspect the pressed depth of E-CVVT plug.
(1)
By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of motor shaft (①).
(2)
By using a steel ruler, measure the distance from E-CVVT cover center boss to the end of E-CVVT plug (②).

(3)
Calculate the pressed depth (③) of motor plug.
If out of specification, reinstall after replacing the E-CVVT plug with a new one.
Pressed depth : ③ = ② - ①
Specification : 1.9 - 2.1 mm (0.0748 - 0.0827 in.)
10.
Insert the E-CVVT cover plug so that the protrusion (A) reach to E-CVVT cover groove correctly.

  
Check how much protrude after installing the E-CVVT plug.

Be careful that the plug is not inserted inside E-CVVT cover beyond the regulated range.
11.
Install the engine support bracket (A).
Tightening torque:
Bolt B : 4.0 - 4.5 kgf·m
Bolt C : 2.0 - 2.5 kgf·m
(1)
Install in order of 1→2→3 temporary.
(2)
Turn the bracket counterclockwise and install the bolt 1.
(3)
Install in order of 2→3→4→5→6 .

12.
Install the other parts in the reverse order of removal.
  
Refill engine with engine oil.
Refill a transaxle with fluid.
Refill a radiator and a reservoir tank with engine coolant.
Clean battery posts and cable terminals and assemble.
Inspect for fuel leakage.
After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
Refill radiator and reservoir tank with engine coolant.
Bleed air from the cooling system.
Front Oil Seal Repair procedures
Replacement 1. Remove the crankshaft damper pulley. (Refer to Timing System - "Crankshaft Damper Pulley") 2. Remove t ...

Timing Chain Repair procedures
Removal 1. Remove the cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover") 2. Turn the cran ...

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