Repair Procedures: Installation

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

The TDC marks of the intake and exhaust CVVT sprockets are slightly turned from the TDC position as shown when the timing chain is removed.

Fig 1: Checking Intake And Exhaust CVVT Sprockets Turning Angle
Courtesy of KIA MOTORS AMERICA, INC.
Turn the crankshaft clockwise (about 1~2 pitches) from the TDC position (the dowel pin (A) of crankshaft is about 3° with the engine vertical line) as rotation of the intake CVVT sprocket from the TDC position.

Fig 2: Turning Crankshaft Clockwise (1-2 Pitches) From TDC Position
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: Locating Timing Chain Guide With Bolts
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: Locating Timing Chain Tensioner Arm With Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain.
Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D)
1. Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
  
  Fig 5: Timing Chain Installation Position
  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: Installing Timing Chain On Exhaust CVVT Sprocket
  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: Locating Timing Chain Auto Tensioner And Stopper Pin With Bolts
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- When reinstall the tensioner, always use new tensioner.
Fig 8: Checking Interference Between Tensioner Arm And Tensioner Housing
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: Checking TDC Marks On Intake And Exhaust CVVT Sprockets For Aligned With Top Surface Of Cylinder Head
Courtesy of KIA MOTORS AMERICA, INC.
Install the other parts 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.