Timing Chain: Installation

Install the balance shaft chain. (Refer to LUBRICATION SYSTEM in this group)
Install the crankshaft chain sprocket (B).
Install the timing chain oil jet (A).
Tightening torque:

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

Fig 1: Identifying Timing Chain Oil Jet And Crankshaft Chain Sprocket
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 Crankshaft Key
Courtesy of KIA MOTORS AMERICA, INC.

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

9.8 ~ 11.6N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Fig 4: Identifying 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: Identifying Crankshaft Sprocket, Timing Chain Guide, Intake And Exhaust CVVT Sprocket
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 6: Identifying TDC Mark And Timing Mark
Courtesy of KIA MOTORS AMERICA, INC.
Install timing chain tensioner arm (B).
Tightening torque:

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install timing chain auto tensioner (A) and remove set pin.
Tightening torque:

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

Fig 7: Identifying Timing Chain Tensioner Arm And Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
Install timing chain cover.
1. Using a gasket scraper to remove all the old gasket 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, the liquid sealant Loctite 5900H or THREEBOND 1217H 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: 3.0mm (0.12in.)
  
  Fig 8: Identifying Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
4. After applying liquid sealant Loctite 5900H on timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Sealant should be applied without discontinuity.
  
  Bead width: 3.0mm (0.12in.)
  
  Fig 9: Identifying Sealant
  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:
  
  M6: 7.84 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  M8: 18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
  
  Fig 10: Identifying Cylinder Block
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Install the engine support bracket (C).
Tightening torque:

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

M8 : 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
Install the crankshaft pulley (B).
Tightening torque :

166.6 ~ 176.4N.m (17.0 ~ 18.0kgf.m, 122.9 ~ 130.1lb-ft)
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 11: Installing SST (09231-3K000)
  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 12: Identifying Dust Cover And 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 13: Identifying Holder Nuts, Holder, Ring Gear And 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 14: Installing SST (09231-3D100) Using Transaxle Mounting Bolts And Spacers
  Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A).
Tightening torque :

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

Fig 15: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt tensioner (B) and tensioner pulley.
Tightening torque :

53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)
Install the idler pulley (A).
Tightening torque :

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

Fig 16: Identifying Idler Pulley And Drive Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tensioner pulley bolt is left - handed screw.
Install the air compressor bracket (A).
Tightening torque :

19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 13.7 ~ 14.5lb-ft)

Fig 17: Identifying Air Compressor Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the compressor lower bolts.
Tightening torque :

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

Fig 18: Identifying Compressor Lower Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler pulley→ P/S pump pulley → Idler pulley → Water pump pulley → Tensioner pulley.

Rotate the auto tensioner counter - clockwise. With the tensioner turned, install the drive belt on auto tensioner and then release the tensioner.

Fig 19: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting bracket (A) and connect the ground cable.
Tightening torque :

Bolts (B) & Nut (C) : 63.8 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

Nut (D) : 78.5 ~ 107.9 N.m (8.0 ~ 11.0 kgf.m, 57.9 ~ 79.6 lb-ft)

Fig 20: Identifying Engine Mounting Bracket, Bolts And Nuts
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pan.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant Loctite 5900H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied.
  Sealant : Loctite 5900H or equivalent
  
  Bead width : 3.0mm (0.12in.)
  
  Fig 21: Identifying Oil Pan Sealant Applying Area
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  - When applying sealant gasket, sealant must not protrude into the inside of the oil pan.
  - To prevent leakage of oil, apply sealant gasket on the inner threads of the bolt holes.
3. Install oil pan. Uniformly tighten the bolts in several passes.
  Tightening torque
  
  M9 (B) : 30.4 ~ 34.3N.m (3.1~ 3.5kgf.m, 22.4 ~ 25.3lb-ft)
  
  M6 (C) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.
  
  Fig 22: Identifying Oil Pan And Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: Always use a new drain bolt gasket.
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 : 2.5mm (0.1in.)
  
  Fig 23: Identifying Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the cylinder head cover bolts in the following sequence.
  Tightening torque
  
  1st step: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
  
  2nd step: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 24: Identifying 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 ignition coils (A).
Tightening torque :

3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.4 lb-ft)

Fig 25: Identifying Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Connect the PCV (Positive crankcase ventilation) hose (A).

Fig 26: Identifying Positive Crankcase Ventilation Hose
Courtesy of KIA MOTORS AMERICA, INC.
Connect the ignition coil connectors (A) and the exhaust CMP (Camshaft position sensor) connector (B).

Fig 27: Identifying Ignition Coil Connectors And Exhaust Camshaft Position Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Install the under cover and side cover.
Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Install the air cleaner assembly.
1. Install the air cleaner assembly (E) and then connect the air intake hose.
  Tightening torque
  
  Hose clamp bolt :
  
  2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
  
  Air cleaner assembly bolts :
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
2. Connect the breather hose (C) and the intensifier hose (D).
3. Install the air duct (B).
Install the engine cover (A).

Fig 28: Identifying Engine Cover And Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Connect the battery negative terminal.