Repair Procedures: Installation

Check that the TDC marks on the intake and exhaust CVVT sprockets are slightly turned (about 1 to 2 teeth) from the TDC position after the timing chain has been removed.

Fig 1: Checking TDC Marks On Intake And Exhaust CVVT Sprockets
Courtesy of KIA MOTORS AMERICA, INC.
Turn the crankshaft about 1 to 2 teeth clockwise from the TDC position (approx. 3° clockwise from the engine vertical line), by the same amount of rotation as the intake CVVT sprocket from the TDC position.

Fig 2: Turning Crankshaft 1 To 2 Teeth Clockwise
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain guide (A).
Tightening Torque:

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb.ft)

Fig 3: Installing Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain tensioner arm (A).
Tightening Torque:

18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb.ft)

Fig 4: Installing Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain.
Crankshaft sprocket → Timing chain guide → Intake CVVT sprocket → Exhaust CVVT sprocket
1. Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
  
  Fig 5: Installing Timing Chain Between Crankshaft Sprocket And Intake CVVT Sprocket
  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.
2. Install the timing chain on the exhaust CVVT sprocket with no slack while turning the CVVT assembly clockwise.
  
  Fig 6: Turning CVVT Assembly Clockwise
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - The timing mark of the exhaust CVVT sprocket should be matched with timing mark (color link) of timing chain when installing the timing chain.
  - Press down the timing chain links on the exhaust CVVT sprocket to prevent the sprocket from spinning.
Install the timing chain auto tensioner (A) and remove the stopper pin (B).
Tightening Torque:

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

Fig 7: Installing Timing Chain Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- When installing the tensioner, check that the ratchet of the tensioner functions normally after removing the stopper pin by pushing the tensioner arm (A) as close to the tensioner as possible as displayed below.
- When the tensioner plunger is retracted maximally, there should be no interference between the tensioner arm (A) and the tensioner housing (B).
Fig 8: Pushing Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks on the intake and exhaust CVVT sprockets are aligned with the top surface of cylinder head.

Fig 9: Aligning TDC Marks On Intake And Exhaust CVVT Sprockets With Top Surface Of Cylinder Head
Courtesy of KIA MOTORS AMERICA, INC.
Install the other parts in reverse order of removal.
NOTE:
- Refill engine with engine oil.
- Clean battery posts and cable terminals and assemble.
- 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.