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03 optima balance shaft timing marks

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Removal 1. Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan, and raise engine slightly. Remove engine mount assembly near timing belt cover. 2. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1 . Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley. 3. Remove upper timing belt cover and gasket. Remove stub bolt of engine support bracket, and remove center timing belt cover. Remove lower timing belt cover. 4. Ensure camshaft, crankshaft and oil pump sprocket timing marks are aligned. See Fig. 2 or Fig. 3 . Loosen tensioner pulley center bolt. Move tensioner to relieve timing belt tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1 . 5. Remove plug from left side of cylinder block. Install a .31″ (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 4 . Screwdriver must go in at least 2.36″ (60 mm) or more. If screwdriver will only go in about .79-.98″ (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. 6. To remove timing belt “B” (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 7. Remove crankshaft sensing blade (if equipped). See Fig. 5 . Loosen timing belt “B” tensioner bolt. If reusing timing belt “B”, mark direction of belt rotation for reassembly reference. Remove timing belt “B Inspection 1. Inspect timing belts for damaged teeth and cracking. Ensure belts are not contaminated with oil. Check tensioners for free rotation and grease leakage. Replace components if damaged or if grease leakage exists. 2. Check timing belt auto tensioner for leaks. Hold timing belt auto tensioner upright. Measure rod protrusion above edge of housing. See Fig. 6 . Length should be .47″ (12 mm). Apply 22-44 lbs. (10-20 kg) of force to end of rod. If auto tensioner rod moves more than 0.39″ (1 mm), replace the auto tensioner.

2003 Kia Optima L4-2.4L Timing Belt Service and Repair Manual

3.Turn the crankshaft clockwise and align the timing marks so as to bring the No.1 cylinder to compression top-dead-center position. At this time the timing marks of the camshaft sprocket and the upper surface of the rocker cover should coincide, and the dowel pin of the camshaft sprocket should be at the upper side. Remove the auto tensioner. CAUTION: Rotate the crankshaft clockwise. 4.Remove the timing belt. NOTE: If the timing belt is reused, make an arrow mark indicating the turning direction (or the front of the engine) to make sure that the belt is reinstalled in the same direction as before 6.When the oil pump sprocket nut is removed, first remove the plug at left side of the cylinder block and insert a screwdriver to check the left counter balance shaft in position. Screwdriver used for this purpose should have a shaft 8 mm (0.3 inch) in diameter which can be inserted more than 60 mm (2.36 inch) 7.Remove the oil pump sprocket retaining nut and remove the oil pump sprocket. 8.Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand. 9.Next, remove tensioner “B” and remove timing belt “B”. CAUTION: After timing belt “B” has been removed, do not attempt to loosen bolt while holding sprocket with pliers, etc. 10.Remove the crankshaft sprocket “B” from crankshaft. INSPECTION Sprockets, Tensioner Pulley, and Idler Pulley 1.Check the camshaft sprocket, crankshaft sprocket, tensioner pulley, and idler pulley for abnormal wear, cracks, or damage. Replace as necessary. 2.Inspect the tensioner pulley and the idler pulley for easy and smooth pulley rotation and check for play or noise. Replace as necessary. 3.Replace if there is grease leak


TIMING & BALANCE SHAFT BELTS Removal 1. Disconnect negative battery cable. Position crankshaft with cylinder No. 1 at TDC of compression stroke. See Fig. 1 , Fig. 2 or Fig. 3 . Disconnect battery negative cable. Remove splash shield. Remove cruise control actuator, leaving cable connected. Remove power steering pump, leaving hoses connected. 2. Disconnect alternator wiring. Remove wiring harness from valve cover. Remove alternator and A/C belts (if equipped). Remove valve cover and upper timing belt cover. Remove side engine mount. Remove engine oil dipstick and tube. Remove crankshaft pulley. See Fig. 4 . 3. Support engine. Remove 2 rear bolts from engine center support beam. Lower engine enough to permit removal of lower timing belt cover. Remove rubber seal from belt tension adjuster nut. Remove lower timing belt cover. Inspection With belt or belt covers removed, inspect belts for wear, cracks, or oil soaking. Inspect belt teeth for wear. Replace belt if worn, oil soaked, or cracked. Installation 1. Align White mark on flywheel or drive plate (flexplate) with pointer on block. Ensure camshaft(s) is at TDC for No. 1 cylinder. See Fig. 1 , Fig. 2 or Fig. 3 . Install camshaft timing belt. See Fig. 6 . Align rear timing balance shaft belt pulley by inserting a 6 x 100 mm bolt 2.9″ (74 mm) into alignment access hole. Align groove on front balance shaft pulley with pointer on oil pump body. See Fig. 7 . 2. Adjust timing belt tension by rotating crankshaft counterclockwise until No. 1 piston is at TDC of compression stroke. Loosen, but do not remove, timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on timing belt. Tighten adjustment bolt to specification. See TORQUE SPECIFICATIONS . 3. Reverse removal procedure to complete installation. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS . Adjust drive belts to proper tension


REMOVAL & INSTALLATION TIMING BELT Removal (200SX & 300ZX) 1. Disconnect negative battery cable. Release fuel pressure from system. Raise and support vehicle. Remove right wheel and engine side cover (if necessary). Drain cooling system. Remove cooling fan duct. Remove engine coolant reservoir. Remove actuator and remove radiator hoses. Do not allow coolant to contact drive belts. 2. Remove front upper and lower belt covers. See Fig. 1 . Remove drive belts and set No. 1 cylinder at TDC of compression stroke. Remove idler bracket of compressor drive belt and crankshaft pulley. Remove timing belt by removing timing belt tensioner and return spring Inspection (200SX & 300ZX) Visually inspect condition of timing belt. Inspect for cracks, wear, breaks, and oil/coolant saturation. Installation (200SX & 300ZX) 1. Ensure that piston No. 1 is at TDC of compression stroke. Remove valve covers and loosen all rocker shaft bolts. Do not bend timing belt. Install tensioner and return spring. 2. Turn tensioner clockwise and temporarily tighten lock nut. Install timing belt. Align White lines on timing belt with punch mark on camshaft pulleys and crankshaft pulley. Arrow on timing belt must be pointing toward front belt covers. 3. Using Allen wrench, slowly turn tensioner clockwise and counterclockwise 2 or 3 times. When camshafts and crankshaft marks are aligned, tighten tensioner lock nut. See Fig. 2 . Ensure that camshaft lobes are correctly positioned. Tighten rocker shaft bolts in 2 stages. 4. Refill and bleed air from cooling system. To complete installation, reverse removal procedures. Adjust drive belts to proper tension


REMOVAL & INSTALLATION TIMING BELT Removal 1. Disconnect negative battery cable. Remove engine cover. Using 16-mm spanner wrench, rotate serpentine belt tension arm clockwise about 14 degrees to relieve belt tension. Remove serpentine drive belt. Remove power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1 or Fig. 2 . 2. Ensure timing marks of camshaft sprocket and cylinder head cover are matching. See Fig. 5 . On Sedona, support engine with jack and remove engine mounting insulator. On all models, remove auto tensioner. See Fig. 3 . 3. Unbolt timing belt tensioner pulley, and remove timing belt. CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. NOTE: Rotate crankshaft clockwise and align timing mark to set No. 1 cylinder to TDC on compression stroke. NOTE: If timing belt is to be reused, mark rotational direction on belt for reinstallation reference. CAUTION: If either camshaft is set at TDC for cylinder No. 1 at the compression stroke and the corresponding camshaft on the same cylinder head is rotated 180 degrees while the timing belt is removed, intake and exhaust valves may contact each other Inspection Inspect timing belt for wear on edges of drive teeth. Inspect the belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened Black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Replace if defective. Check timing belt auto tensioner for leaks. Replace if necessary. Installation 1. Install timing belt idler pulley to engine support lower bracket. Install tensioner arm, shaft and washer to cylinder block. Tighten tensioner arm bolt to specification. See TORQUE SPECIFICATIONS . 2. Install crankshaft sprocket and align timing mark. See Fig. 4 . Install camshaft sprocket and adjust installation positions as shown. See Fig. 5 and Fig. 6 . Install auto tensioner to oil pump case. Ensure that