Campaign - Upper Timing Cover Replacement

VOLUME
2

GROUP
Campaign

NUMBER
019

MODEL
Optima

DATE
March 2001

SUBJECT:
Timing Belt Cover - Service Campaign

This bulletin provides information on a service campaign to install a revised upper timing belt cover on Optima 4 cylinder engines.

In 2001 MY Optima 4 cylinder models produced before 1/30/01, there is a potential for the engine timing belt to jump out of time at the exhaust camshaft drive pulley. Should this occur, rough engine idle and possible engine damage could result.

Vehicles produced after 1/30/01 incorporate a revised upper timing belt cover to prevent this condition.





To prevent possible timing belt jump in 4 cylinder Optimas produced before 1/30/01, Kia is conducting a service campaign to install a revised upper timing belt cover on the affected vehicles both in customer service and in dealer inventory.

* NOTICE
There is no charge to the customer for this repair. Use the procedures provided in this bulletin to install the revised timing cover.

INSPECTION:

1. Verify production date is before 1/30/01.

2. Open hood and look for a white paint mark on engine support threaded stud.





3. If white paint mark exists, NO FURTHER ACTION IS REQUIRED.

4. If white paint mark does not exist, continue on to the Repair Procedure.

REPAIR PROCEDURE:

1. Remove engine cover.





2. Remove upper timing belt cover.

3. Rotate engine to # 1 TDC mark on crankshaft pulley.





4. Check position of timing marks on intake and exhaust camshaft pulleys. The marks must line up with corresponding marks on rocker cover.





5. A. If cam timing is correct, install new upper timing belt cover. NO FURTHER ACTION IS REQUIRED. Apply campaign completion label in location shown.

B. If cam timing is not correct, continue on to Step 6.

6. Raise vehicle enough to have the wheels on the ground while still able to work under the hood.

7. Remove right front wheel/tire assembly.





8. Remove lower splash guard bolts (3) and remove guard.





9. Loosen power steering mounting and tensioner bolts, remove belt.





10. Loosen alternator mounting and tensioner bolts, and remove alternator/waterpump belt.





11. Remove bolts (4) securing crankshaft pulley/vibration damper to crankshaft, and remove pulley.





12. Remove bolts (4) securing water pump pulley to pump, and remove pulley.





13. Remove bolts (9) securing lower timing belt cover to engine, and remove cover.

14. Insert a spreader (Snap-on GA395 or equivalent) between idler and tensioner pulleys.





Using thumbscrew, slowly apply pressure to the tensioner until firm resistance is felt. Allow tensioner time to compress, then apply more pressure, and repeat procedure until the locking pin can be inserted in tensioner. Locking pin is normally supplied with new tensioner replacement part. A 1" long steel office type T-pin (1/32" - 3/64" diameter) may be used as a substitute.

* NOTICE
Do not use undue force or sharp or rough-edged tools to move tensioner as damage to the timing belt may occur. If no suitable spreader is available, remove tensioner by loosening two attaching bolts. Compress per above in soft-jawed vice, install locking pin and reinstall tensioner on engine.





15. Set timing by aligning the marks on crankshaft, oil pump sprocket and both camshaft pulleys with corresponding marks on engine. Adjust belt position as necessary.

* NOTICE
Do not rotate engine if camshaft timing is more than two teeth off; valve/piston contact may occur resulting in engine damage.





16. Verify that all marks are aligned while applying hand pressure to tensioner. If correct, remove locking pin from tensioner. Make sure all slack is taken up (rotate crankshaft back and forth as required) and allow tensioner to stabilize for 15 minutes.

17. Rotate crankshaft two full turns, then recheck camshaft pulley timing. If incorrect, repeat step 15 and 16.

* NOTICE
Due to the diameter/ratio difference between crankshaft and oil pump sprockets, the oil pump sprocket will appear out of time after turning crankshaft 2 revolutions. Provided it was set correctly when you first adjusted the belt in step 15, there is no need to reset.





18. Reinstall lower timing belt cover, pulleys, belts and splash shield in reverse order of disassembly.

19. Install right front wheel and torque lug nuts to 66-81 lbs-ft. and lower vehicle.

20. Install new upper timing belt cover.

21. Reinstall engine cover.





22. Apply campaign completion label in location shown.

AFFECTED PRODUCTION RANGE:
2001 Optima models with 4 cylinder engine produced before 1/30/01.





PART NUMBER INFORMATION:





WARRANTY CLAIM INFORMATION: