KIA Sorento 3.

3 V6
G6DB

Timing chain: removal/installation

General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Remove the mass airflow meter

Remove the breather hoses
Remove the air filter
Disconnect the purge control vacuum hose (A)
Disconnect the positive crankcase ventilation hose (B)
Disconnect the throttle control linkage (C)

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Timing chain: removal/installation
Generalthe air inlet manifold
Remove
Before disconnecting
Disconnect the injection
the battery
wiring cable, check
(A) the audio system security code

Removal the camshaft position sensor electrical connector

Disconnect (B)
Disconnect the battery
earth cables (C)
Remove thethe
Disconnect ancillary
ignition
drive
coil belt
wiring (D)
Remove thethe
Disconnect power
condenser
steeringconnector
pump (E)
Remove thethe
Disconnect air-conditioning
oil control solenoid
compressor
valve connector (F)
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Remove the cylinder head cover

Remove the gasket(s)
Turn the crankshaft to TDC for cylinder 1
Remove
Align thethe
crankshaft
coolant timing
pump pulley
marks
Remove
Note: Dothe
notinlet
turnmanifold
the engine anti-clockwise
Remove
Check thethe
camshaft
engine gearwheel
upper covermarks
Remove the resonator
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

When the timing marks are misaligned, rotate the crankshaft 360 degrees to align them
Remove the lower oil sump
Use the special tool (SST 09215-3C000)

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Remove the crankshaft pulley
Remove the timing chain cover
Right-hand side
Timing chain: removal/installation
General the tensioner
Compress
Beforethe
Lock disconnecting
tensioner; use
theabattery
lockingcable,
pin check the audio system security code

Removal
Remove the timing chain upper guide rail
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the chain tensioner guide
Remove the ancillary drive belt tensioner
Remove the chain tensioner
Remove the timing chain
Remove the chain guide
Remove the oil pump gearwheel cover

Remove the oil pump chain tensioner

Remove the lower timing chain guide
Remove the coolant pump pulley
Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Remove the oil pump gearwheel

Remove the oil pump chain
Remove the crankshaft gearwheel

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Left-hand side
Remove the timing chain upper guide rail
Remove the chain tensioner guide
Timing chain: removal/installation
Generalthe chain tensioner
Remove
Before disconnecting
Remove the timing chain
the battery cable, check the audio system security code

Removal
Remove the chain guide
Disconnect
Remove thethe
crankshaft
battery gearwheel
Remove the tensioner
ancillary drive
assembly
belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Check the tensioner and idler pulleys; renew if necessary

Check the timing chain for any cracks and excessive wear

Installation
Align the crankshaft timing marks

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Refit the tensioner assembly

Remove the coolant pump pulley

Remove the inlet manifold
Left-hand side
Remove the engine upper cover
Refit the crankshaft gearwheel
Remove the resonator
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Fit the chain guide (20 - 25 Nm)
Remove the air-conditioning compressor
Fit the timing chain onto the crankshaft gearwheel
Remove the alternator
Fit the timing chain onto the inlet camshaft gearwheel
Remove the ancillary drive belt idler pulley
Fit the timing chain onto the exhaust camshaft gearwheel
Remove the ancillary drive belt tensioner
Align the timing marks

Remove the coolant pump pulley

Fit the chain tensioner guide (19 - 22 Nm)
Remove the inlet manifold
Fit the chain tensioner (10 - 12 Nm)
Remove the engine upper cover
Refit the timing chain upper guide rail (10 - 12 Nm)
Remove the resonator
Fit the crankshaft gearwheels
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Oil pump
Refit the oil pump chain
Refit the oil pump gearwheel (19 - 22 Nm)
Right-hand side
Fit the chain guide (20 - 25 Nm)
Fit the timing chain onto the crankshaft gearwheel
Align the timing marks

Remove the coolant pump pulley

Remove the inlet manifold
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Fit the timing chain onto the inlet camshaft gearwheel

Fit the timing chain onto the exhaust camshaft gearwheel
Align the timing marks

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Fit the chain tensioner guide
Fit the chain tensioner (10 - 12 Nm)
Refit the timing chain upper guide rail (10 - 12 Nm)
Timing chain: removal/installation
General
Oil pump
Before
Fit the chain
disconnecting
guide the battery
(10 -cable,
12 Nm)check the audio system security code

Removal
Refit the oil pump chain tensioner (10 - 12 Nm)
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

on the left- and right-hand sides

Remove the tensioner locking pin
Refit the oil pump gearwheel cover (10 - 12 Nm)

Rotate the engine 2 rotations clockwise by hand

Check the timing marks again
Refit the timing chain cover
Remove
Note: Apply
the sealant
coolant before
pump pulley
fitting (2.5 mm)
Remove
Note: The
the
cover
inletmust
manifold
be fitted within (X) minutes of applying the sealant (X = 5)
Removethe
Renew thegasket
engine upper cover
Remove
Fit the timing
the resonator
chain case oil seal
Remove the oil seal
Use the special tool (SST 09231-3C100)
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Refit the lower oil sump (10 - 12 Nm)

Clean off the old sealant
Note: Apply sealant before fitting (2.5 mm)
Fit the flywheel locking tool (SST 09231-3C300)

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator

Fit the crankshaft pulley (284 - 304 Nm)

Refit the cylinder head cover
Timing chain: removal/installation
General
Note: Apply sealant before fitting (2.5 mm)
BeforeThe
Note: disconnecting
cover mustthe
be fitted
batterywithin
cable,
(X)check
minutes
the of
audio
applying
systemthesecurity
sealantcode (X = 5)

Removal
Renew the gasket
Disconnect
Tightening
thesequence:
battery (1 - 19)
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Reconnect the connector to the solenoid valve (F)

Reconnect the condenser connector (E)
Reconnect the ignition coil wiring (D)
Reconnect the earth cable(s) (C)
Reconnect the camshaft position sensor electrical connector (B)
Reconnect the injection wiring (A)
Remove the coolant pump pulley
Remove the inlet manifold
Remove the engine upper cover
Remove the resonator
Timing chain: removal/installation
General
Before disconnecting the battery cable, check the audio system security code

Removal
Disconnect the battery
Remove the ancillary drive belt
Remove the power steering pump
Remove the air-conditioning compressor
Remove the alternator
Remove the ancillary drive belt idler pulley
Remove the ancillary drive belt tensioner

Install the inlet manifold

Refit the coolant pump pulley
Fit the ancillary drive belt tensioner (96 - 100 Nm)
Fit the tensioner pulley (18 - 22 Nm)

Remove the coolant pump pulley

Remove the inlet manifold
Remove the engine upper cover
Remove the resonator

Refit the ancillary drive belt idler pulley (53 - 58 Nm)

Refit the alternator
Timing chain: removal/installation
General
Refit the air-conditioning compressor
Before
Refit the
disconnecting
power steering
thepump
battery cable, check the audio system security code

Removal
Turn the tensioner anti-clockwise
Disconnect
Fit the ancillary
the battery
drive belt
Remove the
Release thetensioner
ancillary drive belt
Remove thethe
Reconnect power
battery
steering pump

Torque the
Remove settings
air-conditioning compressor
Remove
Chain guide:
the alternator
(20 - 25 Nm)
Remove
Oil pumpthe
gearwheel
ancillary drive belt
(19idler
- 22 pulley
Nm)
Remove thepulley:
Crankshaft ancillary drive belt
(284tensioner
- 304 Nm)
Ancillary drive belt tensioner: (96 - 100 Nm)
Ancillary drive belt idler pulley: (53 - 58 Nm)

Special tools
Oil seal fitting tool: (SST 09231-3C100)
Flywheel locking tool: (SST 09231-3C300)