Timing Belt: Installation

Install the camshaft sprocket and tighten the bolt to the specified torque.
1. Temporarily install the camshaft sprocket bolt (C).
2. Hold the portion (A) of the camshaft with a hexagonal wrench, and tighten the bolt (C) with a wrench (B).
  Tightening torque :
  
  78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)
  
  Fig 1: Tightening Camshaft Sprocket Bolt With Wrench
  Courtesy of KIA MOTORS AMERICA, INC.
Install the cylinder head cover.
1. Install the cylinder head cover (A) and bolts (B).
  Tightening torque :
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 2: Identifying Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the engine cover bracket (A).
  
  Fig 3: Locating Engine Cover Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the PCV (Positive Crankcase Ventilation) hose (A) and breather hose (B) to the cylinder head cover.
  
  Fig 4: Locating Positive Crankcase Ventilation Hose And Breather Hose
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the ignition coil.
  
  Fig 5: Identifying Ignition Coil
  Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft sprocket (A).

Fig 6: Locating Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Align the timing marks of the camshaft sprocket (A) and crankshaft sprocket (B) with the No. 1 piston placed at top dead center and its compression stroke.

Fig 7: Locating Timing Marks Of Camshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.

Fig 8: Locating Timing Marks Of Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the idler pulley (A) and tighten the bolt (B) to the specified torque.
Tightening torque :

42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)

Fig 9: Locating Idler Pulley And Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Temporarily install the timing belt tensioner (A).

Fig 10: Locating Timing Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the belt so as not give slack at each center of shaft. Use the following order when installing timing belt.
Crankshaft sprocket (A) →idler pulley (B) →camshaft sprocket (C) →timing belt tensioner (D).

Fig 11: Locating Crankshaft Sprocket, Idler Pulley, Camshaft Sprocket And Timing Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.

Adjust the timing belt tension.

Loosen the tensioner pulley mounting bolt and apply tension to the timing belt.

Fig 12: Locating Tensioner Pulley Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
After checking the alignment between each sprocket and each timing belt tooth, tighten the mounting bolt (A) and (B) one by one.
Tightening torque :

19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Then recheck the belt tension.
Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (11lb)], the timing belt cog end is approx. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center.

Fig 13: Checking Belt Tension
Courtesy of KIA MOTORS AMERICA, INC.

Timing belt tension measuring procedure [Using a mechanical tension gauge (BT-33-73F, BTG-2 type)] Rotate crankshaft in clockwise direction to set 1st piston on top dead center (TDC) and rotate crankshaft in counterclockwise to 90° then measure the belt tension in the middle of tension side span (in both arrow direction of above illustration) by free vibration method.

CAUTION: When rotating the crankshaft counter-clockwise, be sure to rotate the crankshaft at a time.

Input the belt specifications into the tension meter.

TIMING BELT TENSION MEASURING REFERENCE CHART

Location of measurement		Input data
Location of measurement		M (Mass, g/m.mm)	W (Width, mm)	S (Span, mm)
T1	Camshaft sprocket to crankshaft sprocket	4.5	22	250
T2	Camshaft sprocket to tensioner	4.5	22	231

Locate the micro phone close to the center of belt span (T1, T2) and bounce the belt by finger 2~3 times. Read a value on the display.

Fig 14: Locating Micro Phone Close To Center Of Belt Span (T1, T2)
Courtesy of KIA MOTORS AMERICA, INC.
Measure both T1 and T2 at the A and B points respectively and then calculate the average

Fig 15: Average Belt Tension (T) Equation
Courtesy of KIA MOTORS AMERICA, INC.

Average Belt Tension (T)

Without CVVT (1.4L/1.6L): 20±3.5 kgf

With CVVT (1.6L): 18±3.5 kgf

Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.
Install the timing belt lower cover (A) with 5 bolts (B).
Tightening torque :

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

Fig 16: Locating Timing Belt Lower Cover And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the flange and crankshaft pulley (A), and then tighten crankshaft pulley bolt.
Make sure that crankshaft sprocket pin fits the small hole in the pulley.

Tightening torque :

137.3 ~ 147.1N.m (14.0 ~ 15.0kgf.m, 101.3 ~ 108.5lb-ft)

Fig 17: Locating Flange And Crankshaft Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing belt upper cover (A) with 4 bolts (B).
Tightening torque :

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

Fig 18: Locating Timing Belt Upper Cover And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley and 4 bolts.
Install the power steering pump drive belt (C). (Refer to ELECTRONIC POWER STEERING SYSTEM )

Fig 19: Identifying Power Steering Pump Drive Belt
Courtesy of KIA MOTORS AMERICA, INC.
Install the air conditioner compressor drive belt (B).
(Refer to AIR CONDITIONING SYSTEM )
Install the alternator drive belt (A). (Refer to ALTERNATOR )
Install the RH side cover (A) with 2 bolts (B).

Fig 20: Locating RH Side Cover And Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH front wheel.
Tightening torque :

88.3 ~ 98.1N.m (9.0 ~ 10.0kgf.m, 65.1 ~ 72.3lb-ft)
Install the engine cover with bolts.
Tightening torque :

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

Fig 21: Locating Engine Cover And Bolts
Courtesy of KIA MOTORS AMERICA, INC.