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Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

Install the balance shaft chain. (Refer to INSTALLATION .
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: Crankshaft Key
Courtesy of KIA MOTORS AMERICA, INC.

Fig 3: TDC Marks Aligned
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: Timing Chain & Sprocket Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Timing Chain Mark Aligned With Sprocket Mark
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: Timing Chain Auto Tensioner & 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: Intake And Exhaust CVVT Sprockets TDC Marks In Aligned Position
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: 2.5 mm (0.10 in.)
  
  Fig 11: Sealant Application Areas 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: 3.0 mm (0.12 in.)
  
  Fig 12: Timing Chain Cover Sealant Application Areas
  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: Timing Chain Cover Bolts Tightening Sequence
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).

Fig 15: Installing Crankshaft Front Oil Seal Using SST
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A) and the dust cover (B).
Tightening torque:

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

Fig 16: Water Pump Pulley & Dust Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft pulley (A) and the idler (B).
Tightening torque:

Crankshaft pulley (A):

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

Idler (B)

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

Fig 17: Crankshaft Pulley & Idler
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
Use the SST (09231-3D100, 09231-3D200) to install the crankshaft pulley bolt.
1. Remove the service cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
  
  Fig 18: Service Cover & Transaxle Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
2. Rotate the crankshaft pulley clockwise until a groove (A) on the torsion damper comes in sight.
  
  Fig 19: Torsion Damper Groove
  Courtesy of KIA MOTORS AMERICA, INC.
3. Adjust the length of the holder (A) so that the front plate of the holder (B) puts in the groove at the closest position.
4. Adjust the angle of the links (C) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
  
  Fig 20: Links & Holder
  Courtesy of KIA MOTORS AMERICA, INC.
5. Install the SST (09231-3D100, 09231-3D200) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
Fig 21: Installing SST (09231-3D100, 09231-3D200)
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting support bracket (B).
Tightening torque:

88.3 ~ 107.9 N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6 lb-ft)
Connect the engine ground line (A).
Tightening torque:

10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 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: 2.5 mm (0.10 in.)
  
  Fig 23: Liquid Sealant Applying Area On 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
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: 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:

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

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

Fig 25: A/C Compressor Bracket Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt.
1. Rotate the drive belt #2 tensioner arm (A) clockwise moving the tensioner pulley bolt with wrench. After putting the belt (B) on the tensioner pulley, release the tensioner pulley slowly.
  HSG pulley (1) → Tensioner #1 pulley (2) → Crankshaft pulley (3) → Idler (4) → Tensioner #2 pulley (5)
2. Remove the stopper pin (D) on the drive belt #1 tensioner (C).
Fig 26: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump drive belt (A).
1. Put the SST (09252-03200) between the crankshaft pulley and the drive belt.
2. Rotate the crankshaft pulley clockwise. Then the drive belt is installed.
Fig 27: Installing Water Pump Drive Belt
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: Sealant Application Areas On Cylinder Head Cover
  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.
NOTE:
- 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 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)

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

Fig 32: Wiring Protector & Ignition Coil Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Connect the positive crankcase ventilation (PCV) hose (A).

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

Fig 34: Exhaust Oil Control Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Install the under cover. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the RH front wheel. (Refer to "WHEEL ")
Install the air cleaner assembly. (Refer to ENGINE AND TRANSAXLE ASSEMBLY )
Install the safety plug in the trunk. (Refer to SAFETY PLUG )
Install the engine cover.
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.

NOTE:

Refill engine with engine oil.
Clean battery posts and cable terminals and assemble (12 Volt only).
Inspect for fuel leakage.
- After assembling 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.