Timing Chain: Installation

Install the oil pump chain.
(Refer to LUBRICATION SYSTEM )
Install the crankshaft sprocket (B) .
Install the timing chain oil jet (A) .
Tightening torque:

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

Fig 1: Identifying Crankshaft Sprocket & Timing Chain Oil Jet
Courtesy of KIA MOTORS AMERICA, INC.
Set crankshaft that the key of crankshaft should be aligned with the mating surface of main bearing cap. Put the intake, exhaust camshaft assembly that the TDC mark of intake CVVT sprocket and exhaust camshaft sprocket should be aligned with the top surface of cylinder head. As a result of this, place the piston on No. 1 cylinder at the top dead center on compression stroke.
Install the timing chain guide (A) .
Tightening torque:

9.8 ~ 11.6N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

[Single CVVT]

Fig 2: Identifying Timing Chain Guide (Single CVVT)
Courtesy of KIA MOTORS AMERICA, INC.

[Dual CVVT]

Fig 3: Identifying Timing Chain Guide (Dual CVVT)
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain.
To install the timing chain with no slack between each shaft (cam, crank), use the following procedure:

Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket or camshaft sprocket (D) .

[Single CVVT]

Fig 4: Installing Timing Chain (Single CVVT)
Courtesy of KIA MOTORS AMERICA, INC.

[Dual CVVT]

Fig 5: Installing Timing Chain (Dual CVVT)
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: The timing mark of each sprocket should be matched with timing mark (color link) of timing chain at installing timing chain.

[Single CVVT]

Fig 6: Identifying Timing Marks (Single CVVT)
Courtesy of KIA MOTORS AMERICA, INC.

[Dual CVVT]

Fig 7: Identifying Timing Marks (Dual CVVT)
Courtesy of KIA MOTORS AMERICA, INC.
Install timing chain tensioner arm (B) .
Tightening torque:

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install timing chain auto tensioner (A) and remove set pin.
Tightening torque:

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

[Single CVVT]

Fig 8: Identifying Timing Chain Auto Tensioner & Tensioner Arm (Single CVVT)
Courtesy of KIA MOTORS AMERICA, INC.

[Dual CVVT]

Fig 9: Identifying Timing Chain Auto Tensioner & Tensioner Arm (Dual CVVT)
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front) , confirm the timing mark.
Install 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, the liquid sealant Loctite 5900H or THREEBOND 1217H 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 : 2.5mm (0.1in.)
  
  Fig 10: Identifying Liquid Sealant Application Area
  Courtesy of KIA MOTORS AMERICA, INC.
4. After applying liquid sealant Loctite 5900H on timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied.
  
  Sealant should be applied without discontinuity.
  
  Bead width : 2.5mm (0.1in.)
  
  Fig 11: Identifying Liquid Sealant Application Area
  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:
  
  M6: 7.84 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  M8: 18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)
  
  Fig 12: Identifying Cylinder Block Dowel Pins
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Install oil pan.
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant Loctite 5900H should be applied on oil pan.
  The part must be assembled within 5 minutes after the sealant was applied.
  
  Sealant : Loctite 5900H or equivalent
  
  Fig 13: Identifying Sealant Application Area
  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 oil pan.
  Uniformly tighten the bolts in several passes.
  
  Tightening torque
  
  M8 bolts : 26.5 ~ 30.4N.m (2.7 ~ 3.1kgf.m, 19.5 ~ 22.4lb-ft)
  
  M6 bolts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
  
  Fig 14: Installing Oil Pan
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.
Install the air compressor bracket.
Tightening torque:

19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 13.7 ~ 14.5lb-ft)
Install the compressor lower bolts.
Tightening torque:

19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 13.7 ~ 18.1lb-ft)

Fig 15: Identifying Compressor Lower Bolts
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 : 2.5mm (0.1in.)
  
  Fig 16: Identifying Sealant Application Area
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the cylinder head cover bolts as following method.
  Tightening torque
  
  1st step: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
  
  2nd step: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  
  Fig 17: Identifying Tightening Sequence Of Cylinder Head Cover Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  - 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 and connect the ignition coil connectors (A) .

Fig 18: Identifying Ignition Coil Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A).
Tightening torque:

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Install the crankshaft pulley (B).
Tightening torque:

166.6 ~ 176.4N.m (17.0 ~ 18.0kgf.m, 122.9 ~ 130.1lb-ft)
Install the engine support bracket(C).
Tightening torque:

M10 : 39.2 ~ 44.1N.m(4.0 ~ 4.5kgf.m, 28.9 ~ 32.5lb-ft)

M8 : 19.6 ~ 24.5N.m(2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

Fig 19: Identifying Water Pump Pulley, Crankshaft Pulley And Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
- Install the SST (09231-3K000) to hold the ring gear after removing the starter.
  
  Fig 20: Holding Ring Gear
  Courtesy of KIA MOTORS AMERICA, INC.
- Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
1. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the two transaxle mounting bolts (B).
  
  Fig 21: Identifying Dust Cover And Transaxle Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
2. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
3. Adjust the angle of the links (D) so that the two transaxle mounting bolts can be fastened to the original mounted holes.
  
  Fig 22: Identifying Holder, Nut, Ring Gear And Links
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the SST (09231-3D100) using the two transaxle mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
Fig 23: Tightening Bolts And Nuts Of Holder And Links
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt tensioner (A) .
Tightening torque:

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

Fig 24: Identifying Drive Belt-Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the power steering oil pump (A) (HPS only). Refer to REPAIR PROCEDURES .
Install the idler (B) and the drive belt tensioner pulley (C).
Tightening torque:

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

Drive belt tenisioner pulley (C): 53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)

Fig 25: MDPS Identifying Idler Pulley
Courtesy of KIA MOTORS AMERICA, INC.

Fig 26: HPS Identifying Idler Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley→ Power steering oil pump pulley (HPS only) → Idler #2 pulley → Water pump pulley → Tensioner pulley.

Rotate auto tensioner arm (B) the counter-clockwise moving auto tensioner pulley bolt with wrench. After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

Fig 27: MDPS Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.

Fig 28: HPS Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting bracket (A) and then connect the ground cable.
Tightening torque:

63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

Fig 29: Identifying Engine Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the RH side cover.
Tightening torque:

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 7.9lb-ft)
Install the RH front wheel.
Tightening torque:

88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Install the engine cover (B) .
Connect the battery negative cable (A) .

Fig 30: Identifying Engine Cover & Battery Negative Cable
Courtesy of KIA MOTORS AMERICA, INC.