Repair Procedures: Installation

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

Install the balance shaft chain.
(Refer to Lubrication system - "BALANCE SHAFT & OIL PUMP ")
Install the crankshaft chain sprocket (B) and the timing chain oil jet (A).
Tightening Torque:

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

Fig 1: Locate Crankshaft Chain Sprocket And Timing Chain Oil Jet With Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Set the crankshaft so that the key (A) of crankshaft is aligned with the mating surface of main bearing cap. Put the intake and exhaust camshaft assemblies so that the TDC marks (B) of the intake and exhaust CVVT sprockets are 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: Locate Key Of Crankshaft
Courtesy of KIA MOTORS AMERICA, INC.

Fig 3: Align Intake And Exhaust CVVT Sprockets With Top Surface Of Cylinder Head
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 4: Locate Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A).
Tightening Torque:

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

Fig 5: Locate Timing Chain Guide With Bolts
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 Marks Of Sprocket
Courtesy of KIA MOTORS AMERICA, INC.

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

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

Fig 8: Locate 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 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Fig 9: Locate Timing Chain Auto Tensioner And Stopper Pin With Bolts
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 are aligned with the top surface of cylinder head.

Fig 10: Locate TDC Marks On Intake And Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain cover.
(Refer to Timing System - "TIMING CHAIN COVER ")
Install cylinder head cover.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD 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.
- Refill the transaxle with fluid.
- Refill the radiator and the reservoir tank with engine coolant.
- Clean battery posts and cable terminals and assemble.
- Inspect for fuel leakage.
  - After assemble 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.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.