Kia Sportage 1998-02

Timing Belt Rear Cover

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove the alternator drive belt.
  8.  
  9. Remove the fresh air duct from the top of the radiator.
  10.  
  11. Remove the upper radiator hose.
  12.  
  13. Remove the 4 attaching nuts to the clutch fan.
  14.  
  15. Remove the 5 fan shroud bolts. Remove the fan and shroud as an assembly.
  16.  
  17. Remove the 4 splash guard mounting bolts and the splash guard.
  18.  
  19. Loosen the lockbolts and loosen the air conditioning drive belt.
  20.  
  21. Loosen the power steering lock and mounting bolt. Remove the power steering belt.
  22.  
  23. Remove the 5 upper timing belt cover bolts and remove the cover.
  24.  
  25. Remove the 2 lower timing belt cover bolts and remove the cover.
  26.  
  27. Align the timing marks.
    NOTE
    When aligning the cam pulleys with the seal plate marks, align the left cam pulley I mark and the right cam pulley on the E mark.


    WARNING
    When aligning the timing marks, do not turn the timing gear counterclockwise. Damage to the engine will occur.

  28.  
  29. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten the tensioner bolt to relieve the pressure against the timing belt.
  30.  
  31. Remove the timing belt.
  32.  
  33. Remove the camshaft pulley attaching bolts. Use a driver placed through one of the holes in the pulley to prevent it from moving when the attaching bolt is removed. Remove and mark the pulleys.

    Click image to see an enlarged view

    Fig. Align the crankshaft marks before removing the timing belt - 2.0L (VIN 3) Engine



    Click image to see an enlarged view

    Fig. Proper alignment of the intake and exhaust camshaft pulley timing marks- 2.0L (VIN 3) Engine



    Click image to see an enlarged view

    Fig. Exploded view of timing belt and related components - 2.0L (VIN 3) Engine

  34.  
  35. Remove the valve cover as follows:
    1. Remove one bolt and the resonance chamber, and then remove the two accelerator cable bracket bolts from the valve cover.
    2.  
    3. Remove the two air intake tubes-to-valve cover bolts.
    4.  
    5. Disconnect the accelerator cable by pulling back on the throttle shaft and rotating the accelerator cable until it lines up with the slot in the pulley.
    6.  
    7. Loosen the air hose clamp from the air intake hose to the MAF sensor.
    8.  
    9. Remove the IAC and breather hoses, and the vacuum line from the air intake tube.
    10.  
    11. Remove the three bolts from the air intake tube to the throttle body and remove the air intake tube and air intake hose as an assembly.
    12.  
    13. Remove the six coil cover bolts from the top of the valve cover.
    14.  
    15. Disconnect the electrical connectors from the ignition coils.
    16.  
    17. Remove the four bolts (two each) from the ignition coils to the valve cover.
    18.  
    19. Remove the spark plug wires from the spark plugs.
    20.  
    21. Remove the 15 valve cover bolts.
    22.  
    23. Remove the valve cover.
    24.  

  36.  
  37. Remove the two bolts securing the rear timing belt cover to the cylinder head and remove the cover.

    Click image to see an enlarged view

    Fig. Rear timing belt cover mounting bolt locations - 2.0L (VIN 3) Engine

  38.  

To install:

  1. Install the rear cover to the cylinder head and tighten the two retaining bolts to 90 inch lbs. (10 Nm).
  2.  
  3. Install the valve cover as follows:

    Click image to see an enlarged view

    Fig. Place a small amount of sealer at the corners of the float camshaft caps and the distributor mounting cap - 2.0L (VIN 3) Engine

    1. Place a small amount of sealer at the corners of the float camshaft caps and the distributor mounting cap.
    2.  
    3. Place valve cover on top of cylinder head.
    4.  
    5. Secure cover with 15 bolts and tighten to 35-52 inch lbs. (4-6 Nm).
    6.  
    7. Install the ignition coils and connect the spark plug wires to the spark plugs.
    8.  
    9. Fasten the two coils to the valve cover with the four mounting bolts and tighten to 60 inch lbs. (6.8 Nm).
    10.  
    11. Connect the two ignition coil connectors.
    12.  
    13. Install coil cover and secure with six bolts. Tighten to 30-40 inch lbs. (3-5 Nm).
    14.  
    15. Install air intake hose and air intake tube as an assembly. Secure air intake tube to throttle body with three bolts and tighten to 18 ft. lbs. (24 Nm).
    16.  
    17. Install the two air intake tube-to-valve cover bolts and tighten to 16 ft. lbs. (22 Nm).
    18.  
    19. Connect the accelerator cable by pulling back on the throttle shaft pulley and inserting the cable in the slot. Release the throttle to the closed position.
    20.  
    21. Install the IAC and breather hoses, and the vacuum line to the air intake tube.
    22.  
    23. Connect the air intake hose to the MAF sensor and tighten the clamp.
    24.  
    25. Install the resonance chamber and secure with one bolt. Tighten the two clamps.
    26.  

  4.  
  5. Install the camshaft pulleys. Tighten the bolts to 35-48 ft. lbs. (47-65 Nm).
  6.  
  7. If necessary, align the timing marks.
    NOTE
    When aligning the cam pulleys with the seal plate marks, align the left cam pulley -I- mark and the right cam pulley on the -E- mark.


    WARNING
    When aligning the timing marks, do not turn the timing gear counterclockwise. Damage to the engine will occur.

  8.  
  9. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten tensioner bolt to relieve the pressure against the timing belt.
  10.  
  11. Install the timing belt.
    WARNING
    If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

  12.  
  13. Loosen the tensioner bolt and allow the tensioner to tighten the timing belt. Tighten the tensioner bolt 27-38 ft. lbs. (37-52 Nm).
  14.  
  15. Check the timing belt deflection. If there is more than 0.30-0.33 inch (7.5-8.5mm) replace the tensioner spring.
  16.  
  17. Install the 2 lower timing belt cover bolts to the cover.
  18.  
  19. Install the 5 upper timing belt cover bolts to the cover.
  20.  
  21. Install and adjust the air conditioning and power steering drive belts.
  22.  
  23. Install the splash guard.
  24.  
  25. Install and tighten the alternator belt.
  26.  
  27. Install the upper radiator hose.
  28.  
  29. Install the fan and shroud as an assembly.
  30.  
  31. Install the 4 attaching nuts to the clutch fan.
  32.  
  33. Install the 5 fan shroud bolts.
  34.  
  35. Install the fresh air duct to the top of the radiator.
  36.  
  37. Properly fill the cooling system.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. Start the engine and check for leaks.
  42.  
  43. Road test the vehicle.
  44.  

 
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