Kia Optima: Timing System / Timing Chain Cover

Kia Optima DL3 2019-2025 Service and Repair Manual / Engine Mechanical System / Timing System / Timing Chain Cover

Components and components location

Components

1. Timing chain cover

2. Service plug bolt & gasket

Repair procedures

Removal

Engine removal is not required for this procedure.

•	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 RH front wheel.

3.	Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")

4.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

5.	Remove the drive belt. (Refer to Drive Belt System - "Drive Belt")

6.	Remove the crankshaft damper pulley. (Refer to Drive Belt System - "Crankshaft Damper Pulley")

7.	Remove the water pump. (Refer to Cooling System - "Water Pump")

8.	Remove the drive belt tensioner. (Refer to Drive Belt System - "Drive Belt Tensioner")

9.	Remove the idler. (Refer to Drive Belt System - "Idler")

10.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

11.	Remove the A/C compressor. (Refer to Heating,Ventilation, Air Conditioning - "Compressor")

12.	Drain engine oil and remove the oil pan. (Refer to Lubrication system – “Oil Pan”)

13.	Remove the front engine hanger (A).

14.	Remove the alternator. (Refer to Engine Electrical System - "Alternator")

15.	Remove the engine mounting bracket. (Refer to Engine and Transaxle Assembly - "Engine Mounting")

16.

Remove the timing chain cover (A) by gently prying the gaps between the cylinder head and cylinder block.

•	Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan. (If any impurities are left at the sealing face, oil may leak after reassembly even with the sealant application.)

•	Do not disassemble the oil pump (A) from timing chain cover because it is supplied as timing chain cover & oil pump assembly.

Installation

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 the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.

(3)

Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder block.

Bead width : 3.0 - 5.0 mm (0.11 - 0.20 in.)

Sealant : Threebond 1217H or equivalent

(4)

After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path from oil leakage.

Bead width

Whole section : 2.5 - 3.5 mm (0.10 - 0.14 in.)

Section A : 4.5 - 5.5 mm (0.18 - 0.22 in.)

Section B : 8.0 - 9.0 mm (0.32 - 0.35 in.)

Sealant : Threebond 1217H or equivalent

(5)

Install the timing chain cover. 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 in exact position.

Tightening torque

Bolts (A, B) :

18.6 - 23.5 N•m (1.9 - 2.4 kgf•m, 13.7 - 17.4 lb•ft)

Bolt (C) :

19.6 - 23.5 N•m (2.0 - 2.4 kgf•m, 14.5 - 17.4 lb•ft)

Bolts (D,E) :

39.2 - 49.0 N•m (4.0 - 5.0 kgf•m, 28.9 - 36.2 lb•ft)

Bolt (F) :

9.8 - 11.8 N•m (1.0 - 1.2 kgf•m, 7.2 - 8.7 lb•ft)

Do not reuse the seal bolts (C,F).

The engine running or pressure test should not be performed within 30 minutes after the timing chain cover was assembled.

2.	Replace the front oil seal if necessary. (Refer to Timing System - “Front Oil Seal”)

Install the front engine hanger (A).

Tightening torque :

34.3 - 39.2 N•m (3.5 - 4.0 kgf•m, 25.3 - 28.9 lb•ft)

4.	Install the other parts reverse order of removal.

Add all the necessary fluids and check for leaks. Connect KDS. Check for codes, note, and clear. Recheck.

•	Refill engine with engine oil.

•	Clean battery posts and cable terminals and assemble.

•	Inspect for fuel leakage.

–	After assembling 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.

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