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Repair Procedures: Installation

WARNING: This page is about a different car, the 2013 Kia Sportage and 2012 Kia Sportage. However, it is still accessible from the selected car via links, so may be relevant.

Install the balance shaft chain. (Refer to LUBRICATION SYSTEM ).
Install the crankshaft chain sprocket (B) and 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 Position Of Key
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:

9.8-11.8N.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 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 Sprocket Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.

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

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

Fig 8: Identifying 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:

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

Fig 9: Identifying Timing Chain Auto Tensioner And Stopper Pin
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 Of Intake And 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: 2.5mm (0.10in.)
  
  Fig 11: Identifying Liquid Sealant Applying Area On Gap Between Cylinder Head And 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: 3.0mm (0.12in.)
  
  Fig 12: Identifying Sealant Applying 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):
  
  7.8-9.8N.m (0.8-1.0kgf.m, 5.8-7.2lb-ft)
  
  Bolts B (M8x28):
  
  18.6-22.5N.m (1.9-2.3kgf.m, 13.7-16.6lb-ft)
  
  Bolt C (M8x30):
  
  19.6-24.5N.m (2.0-2.5kgf.m, 14.5-18.1lb-ft)
  
  Bolt D (M10x40):
  
  39.2-44.1N.m (4.0-4.5kgf.m, 28.9-32.5lb-ft)
  
  Bolts E (M10x45):
  
  39.2-44.1N.m (4.0-4.5kgf.m, 28.9-32.5lb-ft)
  
  Fig 13: Identifying Timing Chain 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 crankshaft front oil seal (A) using SST (09214-3K000, 09231-H1100).

Fig 14: Installing Crankshaft Front Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A) and the crankshaft pulley (B).
Tightening torque:

Water pump pulley (A):

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

Crankshaft pulley (B):

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

Fig 15: Identifying Water Pump Pulley And Crankshaft Pulley
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 (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 16: 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 17: Identifying Ladder Frame Dust Cover
  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 18: Identifying Holder, 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 19: Tightening Holder And Links Bolts
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 20: Identifying Drive Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the idler (A) and the drive belt tensioner pulley (B).
Tightening torque:

Idler (A):

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

Drive belt tensioner pulley (B):

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

Fig 21: Identifying Drive Belt Tensioner Pulley And Idler
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tensioner pulley bolt is left-handed screw.
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: Identifying Engine Mounting Support Bracket With 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: 2.5mm (0.10in.)
  
  Fig 23: 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 the oil pan (A). Uniformly tighten the bolts in several passes.
Tightening torque

Bolts B (M9):

30.4-34.3N.m (3.1-3.5kgf.m, 22.4-25.3lb-ft)

Bolts C (M6):

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

Fig 24: Identifying Oil Pan
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:

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

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

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

Fig 26: Identifying A/C Compressor Lower Bolts

G07423449

Courtesy of KIA MOTORS AMERICA, INC.

Install the drive belt (B).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley → Idler #2 pulley → Water pump pulley → Tensioner pulley.

Rotate the drive belt tensioner arm (A) 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: 2.5mm (0.10in.)
  
  Fig 28: Identifying Sealant Applying Area On Upper Area Between Timing Chain Cover And 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: 3.9-5.9N.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 29: Identifying Cylinder Head Cover
Courtesy of KIA MOTORS AMERICA, INC.

Fig 30: Tightening Sequence Of Cylinder Head Cover
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:

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

Fig 31: Identifying Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Install the wiring protector (B), and then connect the ignition coil connectors (A).

Fig 32: Identifying Ignition Coil Connectors And Wiring Protector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the Positive Crankcase Ventilation (PCV) hose (A).

Fig 33: Identifying Positive Crankcase Ventilation (PCV) Hose
Courtesy of KIA MOTORS AMERICA, INC.
Connect the exhaust Oil Control Valve (OCV) connector (A).

Fig 34: Identifying Exhaust Oil Control Valve (OCV) Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the breather hose (A).

Fig 35: Identifying Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH side cover.
Tightening torque:

8.8-10.8N.m (0.9-1.1kgf.m, 6.5-8.0lb-ft)
Install the under cover. (Refer to ENGINE AND TRANSAXLE ASSEMBLY ).
Install the RH front wheel. (Refer to WHEEL .
Connect the battery negative terminal.
Tightening torque:

Without battery sensor:

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

With battery sensor:

4.0-6.0N.m (0.4-0.6kgf.m, 3.0-4.4lb-ft)
Install the engine cover.