Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.

Remove the cylinder head cover.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")
Turn the crankshaft damper pulley so that No. 1 piston is at top dead center.
1. Turn the crankshaft damper pulley and align its groove with the timing mark on the timing chain cover (0° mark on the timing scale).
  
  Fig 1: Aligning Crankshaft Damper Pulley Groove With Timing Mark Of Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
2. Check that the TDC timing marks on the intake and exhaust CVVT sprockets are in a straight line on the cylinder head surface as shown below. If not, turn the crankshaft damper pulley by one revolution (360°).
  
  Fig 2: Locating TDC Timing Marks On Intake And Exhaust CVVT Sprockets
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Do not turn the crankshaft damper pulley counterclockwise.
3. Mark the timing chain links corresponding to the timing marks on the CVVT sprockets with a white marker.
Fig 3: Marking Timing Chain Links Corresponding To Timing Marks On CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Remove the exhaust oil control valve (OCV) adaptor (A).

Fig 4: Locating Exhaust Oil Control Valve Adaptor
Courtesy of KIA MOTORS AMERICA, INC.
Remove the camshaft bearing caps (A) in the order of image below.

Fig 5: Removing Camshaft Bearing Caps
Courtesy of KIA MOTORS AMERICA, INC.

Fig 6: Camshaft Bearing Caps Loosening Sequence

G11822916

Courtesy of KIA MOTORS AMERICA, INC.

Remove the engine mounting support bracket.
1. Put a jack under the oil pan.
  
  Fig 7: Placing Jack Under Oil Pan
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Place a wooden block between the jack and the oil pan to prevent damage to the oil pan.
2. Disconnect the engine ground cable (A).
  
  Fig 8: Removing Engine Ground Cable
  Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the engine mounting support bracket (A).
  
  Fig 9: Removing Engine Mounting Support Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
4. Lift the engine slightly using the jack to obtain space for releasing the timing chain tensioner.
Remove the bolt (A) from the service hole in the timing chain cover.

Fig 10: Locating Timing Chain Cover Service Hole Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Lock the timing chain tensioner in the fully retracted position.
1. Insert a pick into the service hole in the timing chain cover and lower the hole in the left side of the ratchet plate (A) on the tensioner to allow the pawl (B: located inside the tensioner behind the ratchet plate) to be lifted.
  
  Fig 11: Lowering Service Hole In Left Side Of Ratchet Plate
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 12: Lifting Pawl
  Courtesy of KIA MOTORS AMERICA, INC.
2. With the pawl lifted, have a helper pull up the exhaust CVVT & camshaft (A) to allow the tensioner plunger (B) to retract.
  
  Fig 13: Pulling Up Exhaust CVVT And Camshaft
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 14: Tensioner Plunger Retraction
  Courtesy of KIA MOTORS AMERICA, INC.
3. With the tensioner plunger in the fully retracted position, raise the hole in the left side of the ratchet plate (A) again through the service hole in the chain cover to align the ratchet plate hole with the hole in the tensioner body behind the ratchet plate, then lock the tensioner by inserting the pick through the ratchet plate and tensioner body holes.
  
  Fig 15: Raising Hole In Left Side Of Ratchet Plate Through Service Hole Of Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
Separate the exhaust camshaft (A) from the exhaust CVVT by removing the bolt.

Fig 16: Removing Exhaust Camshaft Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the exhaust CVVT (A) from the timing chain.

Fig 17: Locating Exhaust CVVT
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake CVVT & camshaft (A).

Fig 18: Locating Intake CVVT And Camshaft
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Fasten the timing chain to the engine hanger with a cable tie or strap not to allow the timing chain to fall down when removing the intake CVVT & camshaft.

Fig 19: Fastening Timing Chain To Engine Hanger With Cable Tie Or Strap
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake CVVT (A) from the intake camshaft (B).

Fig 20: Removing Intake CVVT From Intake Camshaft
Courtesy of KIA MOTORS AMERICA, INC.

Information

When removing the CVVT bolt, hold the hexagonal portion (B) on the camshaft with a wrench to prevent the camshaft from rotating.