Kia_Sedona_2002-2006

Timing Chain, Sprockets, Front Cover & Seal

Print

Removal & Installation



3.8L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Record the radio anti theft code data.
  4.  
  5. Remove the engine from the vehicle.
  6.  
  7. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
  8.  
  9. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
  10.  
  11. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
  12.  
  13. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
  14.  
  15. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
  16.  
  17. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
  18.  
  19. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
  20.  
  21. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
    NOTE
    Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.

  22.  
  23. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
  24.  
  25. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
  26.  
  27. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
  28.  
  29. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
  30.  
  31. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.

    Click image to see an enlarged view

    Fig. Timing chain and related components-3.8L Engine

  32.  

To install:

  1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
  2.  
  3. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
  4.  
  5. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
  6.  
  7. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
  8.  
  9. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
  10.  
  11. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
  12.  
  13. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.

    Click image to see an enlarged view

    Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine

  14.  
  15. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
  16.  
  17. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
  18.  
  19. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
  20.  
  21. Install the crankshaft sprocket, oil pump and right camshaft drive.
  22.  
  23. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
  24.  
  25. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
  26.  
  27. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.

    Click image to see an enlarged view

    Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine

  28.  
  29. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
  30.  
  31. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
  32.  
  33. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
  34.  
  35. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
  36.  
  37. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
  38.  
  39. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
  40.  
  41. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
  42.  
  43. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
    NOTE
    Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.



    Click image to see an enlarged view

    Fig. Sealant application (1 inch bead width)-3.8L Engine

  44.  
  45. Apply sealant on the chain cover.
    NOTE
    The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.



    Click image to see an enlarged view

    Fig. Timing cover sealant application-3.8L Engine

  46.  
  47. Install a new gasket to the timing case cover.
    NOTE
    It is important that 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 the correct position.



    Click image to see an enlarged view

    Fig. Timing cover gasket installation (A) gaskets-3.8L Engine

  48.  
  49. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.

    Click image to see an enlarged view

    Fig. Timing cover bolt torque sequence and specification-3.8L Engine

  50.  
  51. Install the timing case cover oil seal.
  52.  
  53. Continue the installation in the reverse order of the removal procedure.
  54.  

 
label.common.footer.alt.autozoneLogo