Use fender covers to avoid damaging painted surfaces.
To avoid damage, carefully disconnect the wiring connectors by holding the connector body.
Label all wires and hoses to avoid incorrect connection.
Be sure to read and observe the "General Safety Information and Caution" before performing any work on the high voltage system. Failure to follow the safety instructions may result in serious electrical injury.
Always disconnect the high-voltage circuit in accordance with the "High Voltage Disconnection Procedure" before performing any work on the high-voltage system to avoid serious electric shock.
Disconnect the high voltage cable. (Refer to "High Voltage Disconnection Procedure" in this group)
Remove the engine cover.
Remove the air cleaner assembly. (Refer to Engine and Transaxle Assembly in this group)
Remove the right front wheel. (Refer to Group SS)
Remove the under cover. (Refer to Engine and Transaxle Assembly in this group)
Turn the crankshaft pulley and align its groove with the alignment mark on the timing chain cover to set the No. 1 cylinder piston to top dead center on the compression stroke.
Disconnect the oil control valve (OCV) connector (A) and disconnect the wiring from the cylinder head cover.
Disconnect the positive crankcase ventilation (PCV) hose (A).
Disconnect the ignition coil connectors (A) and remove the wiring protector (B).
Remove the ignition coils (A).
Remove the cylinder head cover (A).
Remove the water pump drive belt (A).
Install the SST (09252-3D100) between the crankshaft pulley and the drive belt.
Turn the crankshaft pulley clockwise. Then remove the drive belt.
Remove the drive belt.
Turn the No. 1 tensioner arm (A) counterclockwise and align the arm with the two holes of the tensioner stopper (B).
Insert the stopper pin (A) into the stopper holes aligned with the No. 1 tensioner (B).
Remove the drive belt (C) by releasing the tension, turning the No. 2 tensioner arm (D) clockwise.
Remove the air conditioner compressor bracket (A).
Drain the engine oil.
Remove the oil pan (A). Insert the blade of the SST (09215-3C000) between the ladder frame and the oil pan. Cut the applied sealant and remove the lower oil pan.
Loosen one oil pan bolt near each corner of the oil pan, leaving the bolts held in place by about 2 threads. Then remove all remaining oil pan bolts.
Insert the SST between the oil pan and the ladder frame, tapping it with a plastic hammer in the directionarrow.
After tapping the SST with a plastic hammer in the direction of theof the arrow around more than 2/3 of the edge of the oil pan, then remove it from the ladder frame.
Do not pry the SST sharply without tapping. This will damage the SST.
Be careful not to damage the mating surfaces of the ladder frame and the lower oil pan.
Install a jack under the edge of the ladder frame.
Place a wooden block between the ladder frame and the jack.
Be careful not to damage the balance shaft and the oil pump module.
Disconnect the ground cable (A), then remove the engine mount bracket (B).
Remove the crankshaft pulley (A) and the idler pulley (B).
Remove the water pump pulley (A) and the dust cover (B).
Remove the engine support bracket (A).
Remove the timing chain cover (A) by carefully prying at the parts between the cylinder head and the cylinder block.
Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover.
Make sure the crankshaft key is aligned with the mating surface of the main bearing cap. As a result, the No. 1 cylinder piston is at top dead center on the compression stroke.
Release the ratchet using a thin rod. Compress the piston, then insert the stopper pin (A) into the hole in the ratchet to lock the compressed piston. Remove the timing chain tensioner (B).
Remove the timing chain tensioner arm (A).
Remove the timing chain (B).
Remove the timing chain guide (A).
Remove the timing chain oil jet (A) and the crankshaft sprocket (B).
Remove the balance shaft chain.
Inspection
Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
Inspect the CVVT sprocket and the crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
Inspect the tensioner arm and chain guide for excessive wear, cracks, or damage. Replace as necessary.
Make sure the tensioner piston moves smoothly when the ratchet pawl is released with a thin rod.
Inspect the tensioner pulley for excessive oil leakage, abnormal rotation or vibration. Replace if necessary.
Inspect the belt for maintenance and abnormal wear of the ribs. Replace if necessary.
Check the pulleys for vibration during rotation and oil or dust buildup on the V-groove. Replace if necessary.
Drive Belt, Tensioner Pulley, Pulley
Installation
Install the balance shaft chain. (Refer to Lubrication System in this group)
Install the crankshaft chain sprocket (B) and the timing chain oil jet (A).
Tightening torque: 7.8 ~ 9.8 N·m
Position the crankshaft so that the key (A) of the crankshaft is aligned with the mating surface of the main bearing cap. Position the intake and exhaust camshafts so that the TDC marks (B) on the intake and exhaust CVVT sprockets are aligned with the upper surface of the cylinder head. As a result, the No. 1 cylinder piston is at top dead center on the compression stroke.
Install the timing chain guide (A).
Tightening torque: 9.8 ~ 11.8 N·m
Install the timing chain. To install the timing chain without slack between each shaft (camshaft, crankshaft), perform the following procedure. Crankshaft sprocket (A) > Timing chain guide (B) > Intake CVVT sprocket (C) > Exhaust CVVT sprocket (D).
The timing marks on each sprocket must align with the timing marks (colored links) of the timing chain when installing the timing chain.
Install the timing chain tensioner arm (A).
Tightening torque: 9.8 ~ 11.8 N·m
Install the automatic timing chain tensioner (B) and remove the stopper pin (A).
Tightening torque: 9.8 ~ 11.8 N·m
After rotating the crankshaft 2 revolutions in the normal direction (clockwise when viewed from the front), make sure the TDC marks (A) on the intake and exhaust CVVT sprockets are aligned with the upper surface of the cylinder head cover.
Install the timing chain cover.
Using a gasket scraper, remove all old sealant from the gasket surfaces.
The sealant application areas on the timing chain cover and the mating parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and other contaminants.
Before installing the timing chain cover, apply liquid sealant to the gap between the cylinder head and the cylinder block. The part must be assembled within 5 minutes after applying the sealant.
Bead width: 2.5 mm (0.10 in)
Apply a continuous bead of Loctite 5900H or equivalent liquid gasket to the timing chain cover. Assemble the part within 5 minutes after applying the sealant. Apply a continuous bead of sealant to prevent oil leakage paths.
Bead width: 3.0 mm (0.12 in.)
Use the locating pins on the cylinder block and the holes in the timing chain cover as a reference for assembly. The timing chain cover must be positioned accurately. Torque: Bolts A (M6 x 25): 7.8 - 9.8 N·m Bolts B (M8 x 28): 18.6 - 22 N·m
Do not start the engine or perform a pressure test within 30 minutes after installing the timing chain cover.
Install the engine support bracket (A). Torque: M10 bolts: 39.2 - 44 N·m M8 bolts: 19.6 - 24 N·m
Install the front crankshaft oil seal (A) using SST (09214-3K000, 09231-H1100).
Install the water pump pulley (A) and dust cover (B).
Use SST (09231-3D100, 09231-3D200) to install the crankshaft pulley bolt.
Remove the service cover (A) from the bottom of the ladder frame, then remove the two transmission mount bolts (B).
Turn the crankshaft pulley clockwise until the groove (A) on the torsional damper is aligned.
Adjust the length of the holder (A) so that the front plate of the holder (B) engages the groove in the nearest position.
Adjust the angle of the links (C) so that the two transmission mount bolts can be tightened into the original holes.
Install SST (09231-3D100, 09231-3D200) using the two transmission mount bolts and spacers. Tighten the bolts and nuts securely to secure the holder and connections.
Install the engine mount bracket (B).
Tightening torque: 88.3 ~ 108 N·m
Connect the engine ground cable (A).
Tightening torque: 10.8 ~ 13.7 N·m
Remove the jack from the ladder frame.
Install the oil pan.
Using a gasket scraper, remove all old sealant from the gasket surfaces.
Before assembling the oil pan, apply Loctite 5900H liquid gasket or Threebond 1217H or equivalent to the oil pan. Assemble the parts within 5 minutes after applying the sealant.
Bead width: 2.5 mm (0.10 in)
When applying sealant, make sure the sealant does not protrude into the oil pan.
To prevent oil leakage, apply sealant to the internal threads of the bolt holes.
Install the oil pan (A). Tighten the bolts evenly in several passes. Torque: Bolts B (M9): 30.4 - 34 N·m Bolts C (M6): 9.8 - 11.8 N·m
After assembly, wait at least 30 minutes before adding engine oil.
Always use a new drain plug gasket.
Install the air conditioning compressor bracket (A). Torque: Bolts (B): 19.6 - 24 N·m Bolts (C): 20.0 - 33 N·m
Install the drive belt.
Turn the No. 2 drive belt tensioner arm (A) clockwise using a wrench on the tensioner bolt. After installing the belt (B) on the tensioner pulley, slowly release the tensioner pulley.> No. 1 tensioner pulley> Crankshaft torsional damper pulley> Idler pulley> No. 2 tensioner pulley
Remove the stopper pin (D) from the No. 1 drive belt tensioner (C).
Install the water pump drive belt.
Place SST (09252-03200) between the crankshaft pulley and the drive belt.
Turn the crankshaft pulley clockwise. Then install the drive belt (A).
Install the cylinder head cover.
Before assembly, remove the hardened sealant located on the upper mating surface between the timing chain cover and the cylinder head cover.
Assemble within 5 minutes after applying sealant.
Bead width: 2.5 mm (0.10 in)
Install the cylinder head cover (A), tightening the bolts as follows. Torque: 1st step: 3.9 - 5.9 N·m 2nd step: 7.8 - 9.8 N·m
Do not reuse the cylinder head cover gasket.
Do not perform the baking and/or purging test within 30 minutes after installing the cylinder head cover.
Install the ignition coils (A).
Tightening torque: 3.9 ~ 5.9 N·m
Install the wire harness protector (B), then connect the ignition coil connectors (A).
Connect the positive crankcase ventilation (PCV) hose (A).
Connect the connector (A) of the Oil Control Valve (OCV).
Install the under cover. (Refer to Engine and Transaxle Assembly in this group)
Install the right front wheel. (Refer to Group SS - "Wheel")
Install the air cleaner assembly. (Refer to Engine and Transaxle Assembly in this group)
Install the safety plug into the luggage compartment. (Refer to Engine and Transaxle Assembly in this group)
Install the engine cover.
Add all required fluids and check for leaks. Connect the GDS. Check for DTCs, note them, and clear them. Recheck.
Fill the engine with engine oil.
Clean the battery terminals and cable clamps, and connect them (12 Volt only).
Inspect for fuel leaks.
After assembling the fuel line, turn the ignition switch ON (do not operate the starter) so that the fuel pump operates for about two seconds and pressurizes the fuel line.
Repeat this procedure two or three times, then check all fuel line connections for leaks.
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Test yourself
A quick Kia Optima Hybrid Owner's Manual quiz: every answer comes with an explanation and a link to the manual page.
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of the arrow around more than 2/3 of the edge of the oil pan, then remove it from the ladder frame.
> Idler pulley
> No. 2 tensioner pulley
