Kia Sportage 2005-06

Timing Belt & Sprockets

Print

Removal & Installation



2.7L Engine


Click image to see an enlarged view

Fig. Timing belt and related components - 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove right front wheel.
  6.  
  7. Remove 2 bolts and right side cover.
  8.  
  9. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover.
    NOTE
    Always turn the crankshaft clockwise



    Click image to see an enlarged view

    Fig. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover - 2.7L engine

  10.  
  11. Remove drive belt and belt tensioner.
  12.  
  13. Remove the engine mount bracket.
  14.  
  15. Set the jack to the engine oil pan. 
    WARNING
    Place a block of wood between the jack and the pan so not to damage the pan. To avoid damage to the oil pan, do not apply excessive force when supporting the engine.

  16.  
  17. Remove the 2 bolts, 2 nuts and engine mount bracket.

    Click image to see an enlarged view

    Fig.  Remove the 2 bolts, 2 nuts and engine mount bracket (A) - 2.7L engine

  18.  
  19. Remove the power steering pump.
  20.  
  21. Remove the 7 bolts and timing belt upper cover.
  22.  
  23. Remove the crankshaft pulley bolt and crankshaft pulley.
  24.  
  25. Remove the drive belt idler pulley.
  26.  
  27. Remove the 4 bolts and timing belt lower cover.

    Click image to see an enlarged view

    Fig. Remove the engine support bracket (A) - 2.7L engine

  28.  
  29. Remove the engine support bracket.
  30.  
  31. Check that timing marks of the camshaft timing pulleys and cylinder head covers are aligned.
  32.  
  33. If not, turn the crankshaft 1 revolution (360°).
  34.  
  35. Remove timing belt tensioner.
  36.  
  37. Alternately loosen the 2 bolts, and remove the tensioner.
  38.  
  39. Remove the timing belt.
    NOTE
    If the timing belt is reused, make an arrow indicating the turning direction to make sure that the belt is reinstalled in the same direction as before. 

  40.  
  41. Remove the tensioner pulley and timing belt idler pulley.
  42.  
  43. Remove the crankshaft sprocket.
  44.  
  45. Remove camshaft sprockets.
  46.  
  47. Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt and camshaft sprocket.
    WARNING
    Be careful not to damage the cylinder head and valve lifter with the wrench. 

  48.  

To install:

  1. Install the crankshaft sprocket.
  2.  
  3. Align the pulley set key with the key groove the crankshaft sprocket and slide on the crankshaft sprocket.
  4.  
  5. Install the camshaft sprockets and tighten the bolts to the specified torque.
  6.  
  7. Temporarily install the camshaft sprocket bolts. 
  8.  
  9. Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bolts. Tighten to 90-110 Nm (65-80 ft. lbs.) 
  10.  
  11. Install the idler pulley and the tensioner pulley. Tighten to:
    NOTE
    Insert and install the idler pulley to the roll pin that is pressed in the water pump boss.



    Idler pulley bolt: 50-60 Nm (36-43 ft. lbs.) 
     
    Tensioner arm fixed bolt: 35-55 Nm (25-40 ft. lbs.)
     

  12.  
  13. Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston placed at top dead center of its compression stroke.

    Click image to see an enlarged view

    Fig. Timing marks aligned - 2.7L engine

  14.  
  15. Place the timing belt tensioner in a vise.
  16.  
  17. Using a press, slowly press in the push rod. 
  18.  
  19. Align the holes of the push rod and housing, then install a set pin through the holes to keep the push rod, in position. 
  20.  
  21. Release the press. 
  22.  
  23. Install the timing belt tensioner.
  24.  
  25. Temporarily install the tensioner with the 2 bolts. 
  26.  
  27. Alternately tighten the 2 bolts. Tighten to 20-27 Nm (14-20 ft. lbs.) 
  28.  
  29. Install the timing belt.
  30.  
  31. Remove any oil or water on the sprockets, and keep them clean. 

    Click image to see an enlarged view

    Fig. Timing belt installation sequence - 2.7L engine

  32.  
  33. Install the timing belt in this order:

    Crankshaft sprocket (A)
     
    Idler pulley (B)
     
    Camshaft sprocket LH side (C)
     
    Water pump pulley (D)
     
    Camshaft sprocket right side (E)
     
    Tensioner pulley (F)
     

  34.  
  35. Remove the set pin from the tensioner.
  36.  
  37. Rotate the crankshaft 2 turns clockwise and measure the projected length of the auto tensioner at TDC (#1 compression stroke) after 5 minutes. The projected length should be 7-9 mm (0.27-0.31 in.) 

    Click image to see an enlarged view

    Fig. Measuring auto tensioner projected length - 2.7L engine

  38.  
  39. Install the engine support bracket. Tighten to:

    Front bolts: 60-70 Nm (43-51 ft. lbs.) 
     
    Side bolt: 15-22 Nm (11-16 ft. lbs.) 
     

  40.  
  41. Install the timing belt lower cover with 4 bolts. Tighten to 10-12 Nm (7-9 ft. lbs.) 
  42.  
  43. Install the drive belt idler pulley. Tighten to 35-55 Nm (25-40 ft. lbs.) 
  44.  
  45. Install the crankshaft pulley. Make sure that crankshaft sprocket pin fits the small hole in the pulley. Tighten to 180-190 Nm (130-138 ft. lbs.) 
  46.  
  47. Install the timing belt upper cover with 7 bolts.
  48.  
  49. Install the power steering pump.
  50.  
  51. Install the drive belt tensioner and drive belt.
  52.  
  53. Install the engine mount bracket.
  54.  
  55. Install engine mount bracket with 2 nuts and 2 bolts. Tighten to 60-80 Nm (44-59 ft. lbs.). 
  56.  
  57. Install right side cover with 2 bolts.
  58.  
  59. Install right front wheel.
  60.  
  61. Install engine cover.
  62.  

 
label.common.footer.alt.autozoneLogo