Repair Procedures: Installation

Install the balance shaft chain. Refer to BALANCE SHAFT & OIL PUMP .
Install the crankshaft chain sprocket (B) and the timing chain oil jet (A).
Tightening torque:

7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 1: Crankshaft Chain Sprocket & Timing Chain Oil Jet
Courtesy of KIA MOTORS AMERICA, INC.
Set the crankshaft so that the key (A) of crankshaft will be aligned with the mating surface of main bearing cap. Put the intake and exhaust camshaft assembly so that the TDC marks (B) of the intake and exhaust CVVT sprockets will be aligned with the top surface of cylinder head. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 2: Identifying Key Of Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.

Fig 3: Identifying Camshaft Sprocket Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 4: Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D).

Fig 5: Crankshaft Sprocket, Timing Chain Guide, Intake & Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing chain.

Fig 6: Identifying Color Links Of Timing Chain (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Identifying Color Links Of Timing Chain (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain tensioner arm (A).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 8: Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain auto tensioner (B) and remove the stopper pin (A).
Tightening torque:

9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 9: Stopper Pin & Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks (A) on the intake and exhaust CVVT sprockets aligned with the top surface of cylinder head.

Fig 10: Identifying TDC Marks On Intake & Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain cover.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and ladder frame) must be free of engine oil and etc.
3. Before assembling the timing chain cover, liquid sealant Loctite 5900H or equivalent should be applied on the gap between cylinder head and cylinder block. The part must be assembled within 5 minutes after sealant was applied.
  Bead width: 3.0 mm (0.12 in.)
  
  Fig 11: Gap Between Cylinder Head & Cylinder Block
  Courtesy of KIA MOTORS AMERICA, INC.
4. After applying liquid sealant Loctite 5900H or equivalent on the timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path of oil leakage.
  
  Bead width: 3.0 mm (0.12 in.)
  
  Fig 12: Identifying Sealant Application Area Of Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
5. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
  Tightening torque:
  
  Bolts A (M6x25) :
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Bolts B (M8x28) :
  
  18.6 ~ 22.5 N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6 lb-ft)
  
  Fig 13: Identifying Timing Cover Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.
Install the engine support bracket (A).
Tightening torque:

M10 bolts: 39.2 ~ 44.1 N.m (4.0 ~ 4.5kgf.m, 28.9 ~ 32.5 lb-ft)

M8 bolts: 19.6 ~ 24.5 N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1 lb-ft)

Fig 14: Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft front oil seal (A) using SST (09214-3K000, 09231-H1100) (B).

Fig 15: Installing Crankshaft Front Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt tensioner (A).
Tightening torque:

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

Fig 16: Drive Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D).
Tightening torque:

Idler (A) :

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

Water pump pulley (B) :

7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

Crankshaft pulley (C) :

166.6 ~ 176.4 N.m (17.0 ~ 18.0kgf.m, 122.9 ~ 130.1 lb-ft)

Drive belt tensioner pulley (D) :

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

Fig 17: Idler, Water Pump Pulley, Crankshaft Pulley & Drive Belt Tensioner Pulley
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tensioner pulley bolt is left-handed screw.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3K000) to hold the ring gear after removing the starter.
  
  Fig 18: Holding Ring Gear
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
  
  Fig 19: Dust Cover & Transaxle Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
  
  Fig 20: Holder, Nut, Ring Gear & Links
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 21: Tightening Bolts & Nuts Of Holder & Links
  Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting support bracket (B) and connect the ground line (A).
Tightening torque:

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Fig 22: Engine Mounting Support Bracket & Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Remove the jack from the ladder frame.
Install the oil pan.
1. Using a gasket scraper, remove all the old sealant material from the gasket surfaces.
2. Before assembling the oil pan, liquid sealant Loctite 5900H, Threebond 1217H or equivalent should be applied on oil pan. The part must be assembled within 5 minutes after sealant was applied.
  Bead width : 3.0 mm (0.12 in.)
  
  Fig 23: Oil Pan
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  - When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  - To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
3. Install the oil pan (A). Uniformly tighten the bolts in several passes.
  Tightening torque
  
  Bolts B (M9) :
  
  30.4 ~ 34.3 N.m (3.1 ~ 3.5kgf.m, 22.4 ~ 25.3 lb-ft)
  
  Bolts C (M6) :
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 24: Oil Pan Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.
  
  NOTE: Always use a new drain plug gasket.
Install the A/C compressor bracket (A).
Tightening torque:

19.6 ~ 23.5 N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4 lb-ft)

Fig 25: A/C Compressor Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the A/C compressor lower bolts (A).
Tightening torque:

20.0 ~ 33.0 N.m (2.04 ~ 3.36kgf.m, 14.8 ~ 24.3 lb-ft)

Fig 26: A/C Compressor Lower Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley → Idler #2 pulley → Water pump pulley → Tensioner pulley.

Rotate the drive belt tensioner arm (B) counterclockwise moving the tensioner pulley bolt with wrench. After putting the belt on the tensioner pulley, release the tensioner pulley slowly.

Fig 27: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install cylinder head cover.
1. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
2. After applying sealant, it should be assembled within 5 minutes.
  Bead width : 2.5 mm (0.10 in.)
  
  Fig 28: Area Between Timing Chain Cover & Cylinder Head
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the cylinder head cover (A) by tightening the bolts as following method.
  Tightening torque
  
  1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)
  
  2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 29: Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 30: Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  - Do not reuse cylinder head cover gasket.
  - The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
Install the front engine hanger (A).
Tightening torque:

27.5 ~ 31.4 N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1 lb-ft)

Fig 31: Front Engine Hanger
Courtesy of KIA MOTORS AMERICA, INC.
Connect the PCV (Positive crankcase ventilation) hose (A).

Fig 32: PCV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure fuel pump (A) and the roller tappet (B). Refer to INSTALLATION .
Tightening torque:

12.7 ~ 14.7 N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8 lb-ft)

Fig 33: High Pressure Fuel Pump & Roller Tappet
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

NOTE: Do not use already used bolt again.

NOTE: When tightening the installation bolts of the high pressure fuel pump, tighten the bolts in small increments (0.5 turns) after tightening them by hand.

CAUTION: Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

NOTE: Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.

Fig 34: O-Ring, Roller Tappet & Protrusion
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure pipe (A). Refer to INSTALLATION .
Tightening torque:

Bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)

Nuts : 26.5 ~ 32.4 N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9 lb-ft)

Fig 35: High Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not reuse the high pressure pipe.
Connect PCSV (Purge control solenoid valve) connector (A) and tighten the vacuum & PCSV (Purge control solenoid valve) pipe assembly mounting bolts and nut.

Fig 36: PCSV Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).

Fig 37: Fuel Hose & PCSV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the ignition coils (A).
Tightening torque:

3.9 ~ 5.9 N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)

Fig 38: Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Connect the ignition coil connectors (A) and fuel pump connector (B) after installing the wiring protector (C).

Fig 39: Ignition Coils & Fuel Pump Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Connect the exhaust OCV (Oil control valve) connector (A).

Fig 40: Exhaust OCV Connector
Courtesy of KIA MOTORS AMERICA, INC.
Install the under covers (A, B).
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 41: Under Covers
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the cover (B), install the cover with the mounting bracket.
Install the RH front wheel.
Install the air cleaner assembly.
1. Install the air cleaner assembly (E) and then connect the air intake hose (D).
  Tightening torque
  
  Hose clamp bolt :
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts :
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
2. Connect the breather hose (A), the brake booster vacuum hose (B) and the intensifier hose (C).
  
  Fig 42: Breather, Brake Booster Vacuum & Intensifier Hoses
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
  - Install the air intake hose match groove to throttle body groove.
    
    Fig 43: Identifying Air Intake & Throttle Body Grooves
    Courtesy of KIA MOTORS AMERICA, INC.
Install the air duct (C) and the engine cover (B)
Connect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0 N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4 lb-ft)

Fig 44: Battery Negative Terminal, Engine Cover & Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
NOTE:
- Refill engine with engine oil.
- Refill transaxle with fluid.
- Refill radiator and a reservoir tank with engine coolant.
- Clean battery posts and cable terminals and assemble.
- Inspect for fuel leakage.
  - After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  - Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
  - Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
  - Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
  - Put radiator cap on tightly, then run the engine again and check for leaks.