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Repair Procedures: Installation

  1. 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 the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
    3. Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder block.

      Bead width:  3.0 - 5.0 mm (0.11 - 0.20 in.)

      Sealant:  Three bond 1217H or equivalent

      G12826462Courtesy of KIA MOTORS AMERICA, INC.
    4. After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path from oil leakage.

      Bead width 

      Whole section: 2.5 - 3.5 mm (0.10 - 0.14 in.)

      Section A: 4.5 - 5.5 mm (0.18 - 0.22 in.)

      Section B: 8.0 - 9.0 mm (0.32 - 0.35 in.)

      Sealant: Threebond 1217H or equivalent

      G12826463Courtesy of KIA MOTORS AMERICA, INC.
    5. Install the timing chain cover. 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 in exact position.

      Tightening torque 

      Bolts (A, B):

      18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

      Bolt (C):

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

      Bolts (D, E):

      39.2 - 49.0 N.m (4.0 - 5.0 kgf.m, 28.9 - 36.2 lb.ft)

      Bolt (F):

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

      G12826464Courtesy of KIA MOTORS AMERICA, INC.
      NOTE: Always use a new seal bolts (C, F).
      NOTE: The engine running or pressure test should not be performed within 30 minutes after the timing chain cover was assembled.
  2. Replace the front oil seal if necessary.

    (Refer to Timing System - "FRONT OIL SEAL ")

  3. Install the variable force solenoid (VFS) valve (A).

    Tightening torque: 

    8.8 - 9.8 N.m (0.9 - 1.0 kgf.m, 6.5 - 7.2 lb.ft)

    G12826465Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Always use a new actuator bolts.
    • The residue inside of the chain cover bolt hole should be disposed before locking.
    • The actuator bolts should be locked to the regulated torque.
  4. Install the front engine hanger (A).

    Tightening torque: 

    34.3 - 39.2 N.m (3.5 - 4.0 kgf.m, 25.3 - 28.9 lb.ft)

    G12826466Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the other parts reverse order of removal.
  6. Add all the necessary fluids and check for leaks. Connect KDS. Check for codes, note, and clear. Recheck.
    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.
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