Kia Sportage 1998-02

Timing Belt

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General Information



Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valve train of an overhead camshaft engine.

Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:



Does the owner know if, or when the belt was replaced-
 
If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace, or at least inform the owner that the vehicle is equipped with a timing belt.
 
Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).
 

Interference Engines

Engines, chain- or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing is disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

Inspection




NOTE
For manufacturer-s recommended service interval, refer to the maintenance interval chart located in this manual.

The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time.


WARNING
Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.



Click image to see an enlarged view

Fig. Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:



Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail
 
Cracks on the rubber backing
 
Cracks or peeling of the canvas backing
 
Cracks on rib root
 
Cracks on belt sides
 
Missing teeth or chunks of teeth
 
Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife.

Click image to see an enlarged view

Fig. Clean the timing belt before inspection so that imperfections or defects are easier to recognize



Click image to see an enlarged view

Fig. Inspect the timing belt for damage, such as a broken or missing tooth, which may be due to a damaged pulley



Click image to see an enlarged view

Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover



Click image to see an enlarged view

Fig. Side wear from improper installation or a defective pulley plate



Click image to see an enlarged view

Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

 

If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.


WARNING
On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.

Removal & Installation



2.0L (DOHC) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the alternator drive belt.
  6.  
  7. Remove the fresh air duct from the top of the radiator.
  8.  
  9. Remove the upper radiator hose.
  10.  
  11. Remove the 4 attaching nuts to the clutch fan.
  12.  
  13. Remove the 5 fan shroud bolts. Remove the fan and shroud as an assembly.
  14.  
  15. Remove the 4 splash guard mounting bolts and the splash guard.
  16.  
  17. Loosen the lockbolts and loosen the air conditioning drive belt.
  18.  
  19. Loosen the power steering lock and mounting bolt. Remove the power steering belt.
  20.  
  21. Remove the 5 upper timing belt cover bolts and remove the cover.
  22.  
  23. Remove the 2 lower timing belt cover bolts and remove the cover.
  24.  
  25. 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.

  26.  
  27. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten the tensioner bolt to relieve the pressure against the timing belt.
  28.  
  29. Remove the timing belt.
  30.  
  31. 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.
  32.  
  33. Remove the lower timing belt pulley and locking bolt.

    Click image to see an enlarged view

    Fig. Align the crankshaft marks before removing the timing belt-KIA Sportage 2.0L (DOHC) engine



    Click image to see an enlarged view

    Fig. Proper alignment of the intake and exhaust camshaft pulley timing marks-KIA Sportage 2.0L (DOHC) engine

  34.  

To install:

  1. Install the camshaft pulleys. Tighten the bolts to 35-48 ft. lbs. (47-65 Nm).
  2.  
  3. Install the lower timing belt pulley and locking bolt. Tighten the bolt to 120 ft. lbs. (162 Nm).
  4.  
  5. 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.

  6.  
  7. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten tensioner bolt to relieve the pressure against the timing belt.
  8.  
  9. 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.

  10.  
  11. Loosen the tensioner bolt and allow the tensioner to tighten the timing belt. Tighten the tensioner bolt 27-38 ft. lbs. (37-52 Nm).
  12.  
  13. Check the timing belt deflection. If there is more than 0.30-0.33 in. (7.5-8.5mm) replace the tensioner spring.
  14.  
  15. Install the 2 lower timing belt cover bolts to the cover.
  16.  
  17. Install the 5 upper timing belt cover bolts to the cover.
  18.  
  19. Install and adjust the air conditioning and power steering drive belts.
  20.  
  21. Install the splash guard.
  22.  
  23. Install and tighten the alternator belt.
  24.  
  25. Install the upper radiator hose.
  26.  
  27. Install the fan and shroud as an assembly.
  28.  
  29. Install the 4 attaching nuts to the clutch fan.
  30.  
  31. Install the 5 fan shroud bolts.
  32.  
  33. Install the fresh air duct to the top of the radiator.
  34.  
  35. Properly fill the cooling system.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Start the engine and check for leaks.
  40.  
  41. Road test the vehicle.
  42.  

 
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