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Timing Chain: Installation

Install the oil pump chain. Refer to LUBRICATION SYSTEM .
Install the crankshaft 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 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 Key Of Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.

Fig 3: Identifying TDC Marks Of Intake And Exhaust CVVT Sprockets
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 (Single CVVT)

G07367455

Courtesy of KIA MOTORS AMERICA, INC.

Fig 5: Identifying Timing Chain Guide (Dual CVVT)

G07367456

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 or camshaft sprocket (D).

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 Crankshaft Sprocket And Timing Chain Guide (Single CVVT)

G07367464

Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Identifying Crankshaft Sprocket And Timing Chain Guide (Dual CVVT)

G07367464

Courtesy of KIA MOTORS AMERICA, INC.

Fig 8: Identifying Timing Mark Of Sprocket And Timing Chain (Single CVVT)

G07367465

Courtesy of KIA MOTORS AMERICA, INC.

Fig 9: Identifying Timing Mark Of Sprocket And Timing Chain (Dual CVVT)

G07367466

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 10: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm (Single CVVT)

G07367467

Courtesy of KIA MOTORS AMERICA, INC.

Fig 11: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm (Dual CVVT)

G07367468

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, 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, 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 : 2.5mm (0.1in.)
  
  Fig 12: Identifying Sealant Applying Areas Of Cylinder Head And Cylinder Block
  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 : 2.5mm (0.1in.)
  
  Fig 13: Identifying Sealant Applying Area On 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:
  
  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 14: Identifying Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Install 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
  
  Fig 15: Identifying Sealant Applying Area Of 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 oil pan.
  Uniformly tighten the bolts in several passes.
  
  Tightening torque
  
  M8 bolts : 26.5 ~ 30.4N.m (2.7 ~ 3.1kgf.m, 19.5 ~ 22.4lb-ft)
  
  M6 bolts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 16: Identifying Oil Pan And Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.
Install the air compressor bracket.
Tightening torque:

19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 13.7 ~ 14.5lb-ft)
Install the compressor lower bolts.
Tightening torque:

19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 13.7 ~ 18.1lb-ft)

Fig 17: Identifying Compressor Lower Bolts
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 : 2.5mm (0.1in.)
  
  Fig 18: Identifying Sealant Applying Area Of Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the cylinder head cover bolts as following method.
  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 19: 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 and connect the ignition coil connectors (A).

Fig 20: Identifying Ignition Coil Connectors
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)
Install the crankshaft pulley (B).
Tightening torque:

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

Fig 21: Identifying Water Pump Pulley, Crankshaft Pulley And Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
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 22: 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 23: 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 24: Identifying Holder, Nut, 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 25: Tightening Bolts And Nuts Of Holder And Links
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt tensioner (A) .
Tightening torque:

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

Fig 26: Identifying Drive Belt-Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the power steering oil pump (A) (HPS only). Refer to REPAIR PROCEDURES .
Install the idler (B) and the drive belt tensioner pulley (C).
Tightening torque:

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

Drive belt tenisioner pulley (C): 53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)

Fig 27: MDPS Identifying Idler Pulley
Courtesy of KIA MOTORS AMERICA, INC.

Fig 28: HPS Identifying Idler Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley→ Power steering oil pump pulley (HPS only) → Idler #2 pulley → Water pump pulley → Tensioner pulley.

Rotate auto tensioner arm (B) the counter-clockwise moving auto tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

Fig 29: MDPS Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.

Fig 30: HPS Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting bracket (A) and then connect the ground cable.
Tightening torque:

63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

Fig 31: Identifying Engine Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH side cover.
Tightening torque:

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)
Install the RH front wheel.
Tightening torque:

88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Install the engine cover (B).
Connect the battery negative cable (A).

Fig 32: Identifying Battery Negative Cable And Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.