Kia Optima: CVVT & Camshaft Repair procedures - Cylinder Head Assembly - Engine Mechanical SystemKia Optima: CVVT & Camshaft Repair procedures

Removal
1.
Remove the cylinder head cover.
2.
Set No.1 cylinder to TDC/compression.
a.
Turn the crankshaft pulley and align its groove with the timing mark "T" of the lower timing chain cover.


b.
Check that the mark(A) of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft one revolution (360В°)


3.
Remove the bolt (A) from the service hole in the timing chain cover. It might be required to run a M8X1.25 tap in the hole to clean out the lock-tight (sealer) on the threads.
   
   
Ensure that debris does not enter into the engine through the open bolt hole.


4.
Pull and turn the loop (A) on the SST 09240-2G000 to allow the spring loaded shaft (B) to be pulled (locked) against the spring. Add a small amount of light lubricant to the threads of the tool and then thread it into the hole in the timing cover until you can feel it hit the tensioner. Then thread the tool back out about one turn.


5.
Turn the loop to unlock the tool.


6.
Slowly turn the tool counterclockwise. Depending on where the pin on the tool is located, a few clicks may be heard as the pin moves over the pawl and shaft. As you turn, you should be able to feel the spring loaded pawl being lifted. Once lifting the pawl, tighten the lock nut (A) and lift the chain and cam gear onto the cam.


7.
Remove the camshaft.
(1)
Remove the front camshaft bearing cap (A) with the upper bearing (B).


(2)
Remove the camshaft bearing cap (A) in the sequence shown.


(3)
Remove the camshafts (A).


8.
Disconnect the intake CVVT assembly(A) and exhaust CVVT assembly(B) from camshaft(C).


   
   
When removing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position D.
Installation
1.
Install the intakeCVVT assembly(A), exhaust CVVT assembly(B) and camshaft(C).

Tightening torque :
53.9 ~ 63.7 N.m (5.5 ~ 6.5 kgf.m, 39.7 ~ 47.0 lb-ft)


   
   
When installing the CVVT assembly bolt, fix the camshaft by wrench at position D.
2.
Install the camshafts.
   
   
Apply a light coat of engine oil on camshaft journals.
(1)
Install the exhaust camshaft lower bearing (A).


(2)
Install the camshafts (A).


(3)
Install the timing chain
Check that the mark(A) of the CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration.


(4)
Install the exhaust camshaft upper bearing (A) to the front bearing cap.


3.
Install camshaft bearing caps (A) in their proper locations.
Tightening order
Group A > Group B > Group C.

Tightening torque :
Step 1
M6 : 5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
M8 : 14.7 N.m (1.5 kgf.m, 10.8 lb-ft)
Step 2
M6 : 10.8 ~ 12.7 N.m (1.1 ~ 1.3 kgf.m, 8.0 ~ 9.4 lb-ft)
M8 : 27.5 ~ 31.4 N.m (2.8 ~ 3.2 kgf.m, 20.3 ~ 23.1 lb-ft)


4.
Disconnect the SST(A) (09240-2G000).


5.
Install the service hole bolt of the timing chain cover.

Tightening torque :
11.7 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.6 ~ 10.8 lb-ft)


   
   
The bolt must not be reused once it has been assembled.
6.
Install the cylinder head cover.
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