Checking the technical condition of the timing drive

Remove the top cover.

Check the timing belt (A) for damage, oil or coolant ingress

If oil or coolant has leaked onto the belt, you need to replace it

Remove oil from the surface of the belt if it gets on the belt.

GRM drive parts: 1 - crankshaft pulley; 2 - lower cover of the timing belt; 3 - engine mount bracket; 4 - top cover of the timing belt; 5 - timing belt; 6 - generator and vacuum pump assembly; 7 - pulley of the hydraulic booster pump; 8 - air conditioning compressor; 9 - camshaft drive gear; 10 - intermediate pulley of the timing belt; 11 - drive belt tensioner; 12 - intermediate pulley

Check the camshaft gear.

Check the camshaft gear, crankshaft, tensioner pulley, pulley for wear and damage. Replace parts if necessary.

Check the tensioner pulley and pulley for noise by turning them smoothly. Replace parts if necessary.

If the pulley has dirt smudges from the bearing, replace the pulley.

Remove drive

Remove the front right wheel of the car.

Remove the side cover.

D4EA Kia Magentis Diesel Timing Belt Replacement

Pull up the belt tensioner to remove the accessory drive belt (A).

D4EA Kia Magentis Diesel Timing Belt Replacement

Remove the mounting bolts and nuts and remove the engine mounting bracket (A).

D4EA Kia Magentis Diesel Timing Belt Replacement

Remove the mounting bolts and remove the upper timing belt cover (A).

D4EA Kia Magentis Diesel Timing Belt Replacement

Remove the mounting bolts and remove the crankshaft pulley (A).

D4EA Kia Magentis Diesel Timing Belt Replacement

Remove the mounting bolts and remove the lower timing belt cover (A).

If you remove the tensioner, performance will deteriorate.

D4EA Kia Magentis Diesel Timing Belt Replacement

Remove the mounting bolts and remove the motor support bracket (A).

D4EA Kia Magentis Diesel Timing Belt Replacement

Align the alignment marks (A, B) on the camshaft gear (C) and crankshaft gear (D) with the marks (E, F) on the cylinder head (G) and on the oil pump housing (H), turning the crankshaft shaft.

D4EA Kia Magentis Diesel Timing Belt Replacement

Install the pin (A) into the aligned holes in the belt tensioner housing (B).

D4EA Kia Magentis Diesel Timing Belt Replacement

Using a socket wrench (5mm) (A), loosen the locking bolt (B). Then, turn the tensioner (C) clockwise until it stops together with the main bolt (D) and a 12 mm ring wrench (E), tighten the locking bolt (B).

Remove the timing belt.

If the belt is to be reused, it must be marked with the direction of rotation before being removed.

Drive installation

D4EA Kia Magentis Diesel Timing Belt Replacement

Align the timing marks (A) on the camshaft gear (B) with the mark (C) on the cylinder head (D).

D4EA Kia Magentis Diesel Timing Belt Replacement

Align the match marks (A) on the crankshaft gear (B) with the pin (C) installed in the oil pump housing (D).

D4EA Kia Magentis Diesel Timing Belt Replacement

Install the timing belt.

Installation must be carried out in the following sequence: crankshaft gear (B) ► water pump pulley (C) ► intermediate pulley (D) ► camshaft gear (E) ► timing belt tensioner (F).

D4EA Kia Magentis Diesel Timing Belt Replacement

Turn the automatic tensioner (C) counterclockwise until it stops.

D4EA Kia Magentis Diesel Timing Belt Replacement

Turn the crankshaft by hand one full revolution (clockwise) to set the number one piston to TDC

Using the special wrench, tighten the locking bolt. Tightening torque 10- 12 Nm.

Remove lock pin and tensioner (A).

Install the engine lower support bracket. Tighten the fastening bolts with a tightening torque of 43 - 55 Nm.

D4EA Kia Magentis Diesel Timing Belt Replacement

Install the upper (A) and lower cover (B) of the timing belt.

Tighten the mounting bolts with a tightening torque of 7.8 - 11.8 Nm.

D4EA Kia Magentis Diesel Timing Belt Replacement

In order to install the belt (A), you need to lift up the tensioner.

Install the crankshaft pulley. Tighten the fastening bolts with a tightening torque of 30 - 34 Nm.

Install the engine mount bracket.

Install the accessory drive belt as follows: alternator ► power steering ► pulley ► compressor ► crankshaft pulley ► tensioner.

Install the side cover.

Install the right front wheel.