Timing Chain: Installation

Install the jack to the upper oil pan.
The key (A) of crankshaft should be aligned with the timing mark (B) of timing chain cover. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 1: Identifying Timing Mark
Courtesy of KIA MOTORS AMERICA, INC.
Install the tensioner adapter assembly (A).

Fig 2: Identifying Tensioner Adapter Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft sprocket (A) (LH camshaft drive).

Fig 3: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH timing chain guide (A).
Tightening torque:

19.60 ~ 24.50N.m (2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

Fig 4: Identifying LH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.

Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket (C) → Intake camshaft sprocket (D).

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

Fig 5: Identifying Exhaust Camshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.

Fig 6: Identifying Timing Mark
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH timing chain tensioner arm (B).
Tightening torque:

18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
Install the LH chain tensioner (A).
Tightening torque:

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 7: Identifying LH Chain Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH cam-to-cam guide (A).
Tightening torque:

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 8: Identifying LH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft sprocket (A) (Oil pump & RH camshaft drive).

Fig 9: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain (B) and oil pump sprocket (A).
Tightening torque:

18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)

Fig 10: Identifying Oil Pump Chain
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain guide (A).
Tightening torque:

19.60 ~ 24.50N.m (2.0 ~ 2.5kgf.m, 14.17 ~ 18.08lb-ft)

Fig 11: Identifying RH Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the procedure below.

Crankshaft sprocket (A) → Intake camshaft sprocket (B) → Exhaust camshaft sprocket (C).

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

Fig 12: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.

Fig 13: Identifying Intake Camshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain tensioner arm (B).
Tightening torque:

18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
Install the RH timing chain auto tensioner (A).
Tightening torque:

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 14: Identifying RH Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH cam-to-cam guide (A).
Tightening torque:

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 15: Identifying RH Cam-To-Cam Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain guide (A).
Tightening torque:

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 16: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain tensioner assembly (A).
Tightening torque:

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 17: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Pull out the pins of hydraulic tensioners (LH & RH).

Fig 18: Pulling Out Pins Of Hydraulic Tensioners (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 19: Pulling Out Pins Of Hydraulic Tensioners (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain cover (A).
Tightening torque:

9.80 ~ 11.76Nm (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)

Fig 20: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE: Always turn the crankshaft clockwise.
Install the timing chain cover.
1. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC.
2. Before assembling the timing chain cover, the liquid sealant TB1217H 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 21: Identifying Sealant Location
  Courtesy of KIA MOTORS AMERICA, INC.
3. After applying liquid sealant TB1217H on the 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 22: Identifying Liquid Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 23: Identifying Gasket
  Courtesy of KIA MOTORS AMERICA, INC.
  
  NOTE: During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.
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:
  
  B (17) :18.62 ~ 21.56N.m (1.9 ~ 2.2kgf.m, 13.74 ~ 15.91lb-ft)
  
  C (4) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  D (1) :58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
  
  E (1) :58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
  
  F (2) :24.50 ~ 26.46N.m (2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft)
  
  G (4) :21.56 ~ 23.52N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft)
  
  H (1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  I (1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  J (1) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  K (4) :9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  L (1):21.56 ~ 26.46N.m (2.2 ~ 2.7kgf.m, 15.91 ~ 19.53lb-ft) - New bolt
  
  Fig 24: Identifying Dowel Pins
  Courtesy of KIA MOTORS AMERICA, INC.
6. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Install the water pump pulley (A).
Tightening torque:

7.84 ~ 9.80N.m (0.8 ~ 1.0kgf.m, 5.78 ~ 7.23lb-ft)

Fig 25: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt auto tensioner (A).
Tightening torque:

Bolt (B):81.39 ~ 85.32N.m (8.3 ~ 8.7kgf.m, 60.03 ~ 62.93lb-ft)

Bolt (C):17.64 ~ 21.56N.m (1.8 ~ 2.2kgf.m, 13.02 ~ 15.91lb-ft)

Fig 26: Identifying Drive Belt Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt idler (A).
Tightening torque:

52.92 ~ 57.82N.m (5.4 ~ 5.9kgf.m, 39.06 ~ 42.67lb-ft)

Fig 27: Identifying Drive Belt Idler
Courtesy of KIA MOTORS AMERICA, INC.
Lower the engine assembly by using the jack.
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 28: Installing Timing Chain Cover Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Using SST (09231-3C300) install the crankshaft damper pulley (A).
Tightening torque:

284.2~303.8N.m (29.0~31.0kgf.m, 209.76~224.22lb-ft)

Fig 29: Installing Crankshaft Damper Pulley
Courtesy of KIA MOTORS AMERICA, INC.

Fig 30: Identifying Special Tool
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → idler pulley → alternator pulley → water pump pulley → P/S pump pulley → tensioner pulley.

Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.

After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.

Fig 31: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install the 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 (TB1217H), it should be assembled within 5 minutes.
  Bead width: 2.5mm (0.1in.)
  
  Fig 32: Identifying Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
3. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
4. Install the cylinder head cover bolts as following method.
  Tightening torque:
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 33: Identifying Cylinder Head Cover Bolts Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: Do not reuse cylinder head cover gasket.
5. Install the ignition coil.
6. Connect the RH ignition coil connector (A), the condenser connector (B) and install the wiring bracket (C).
  
  Fig 34: Identifying RH Ignition Coil Connector
  Courtesy of KIA MOTORS AMERICA, INC.
7. Install the connector bracket (A) to the LH cylinder head cover.
  
  Fig 35: Identifying Connector Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
Install the surge tank and wiring connectors.
1. Install the surge tank (A).
  Tightening torque:
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 36: Identifying Surge Tank
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install the connector bracket (A) to the surge tank.
  Tightening torque:
  
  6.86 ~ 10.78N.m (0.7 ~ 1.1kgf.m, 5.06 ~ 7.96lb-ft)
  
  Fig 37: Identifying Connector Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the surge tank stay.
  Tightening torque:
  
  27.44 ~ 31.36N.m (2.8 ~ 3.2kgf.m, 20.25 ~ 23.14lb-ft)
  
  Fig 38: Identifying Surge Tank Stay
  Courtesy of KIA MOTORS AMERICA, INC.
4. Connect the brake vacuum hose.
5. Connect the PCV hose (C).
6. Connect the water hoses (B) to the ETC.
7. Install the ETC bracket (A).
  
  Fig 39: Identifying ETC Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
8. Connect the LH CMPS connector (A) and oil pressure switch connector (B).
  
  Fig 40: Identifying LH CMPS Connector
  Courtesy of KIA MOTORS AMERICA, INC.
9. Install the wiring harness protector (E) and connect the LH ignition coil connector (A), injector connector (B), condenser connector (C) and ground (D).
  
  Fig 41: Identifying Wiring Harness Protector
  Courtesy of KIA MOTORS AMERICA, INC.
10. Connect the LH front oxygen sensor connector (A).
  
  Fig 42: Identifying LH Front Oxygen Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
11. Connect the OCV connector (A) and knock sensor connector (B).
  
  Fig 43: Identifying OCV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
12. Connect the ETC connector (A) and knock sensor connector (B).
  
  Fig 44: Identifying ETC Connector
  Courtesy of KIA MOTORS AMERICA, INC.
13. Connect the PCSV connector (A), MAP sensor connector (B) and PCSV hose.
  
  Fig 45: Identifying PCSV Connector
  Courtesy of KIA MOTORS AMERICA, INC.
14. Connect the RH injector connector (A) and ignition coil connector (B).
  
  Fig 46: Identifying RH Injector Connector
  Courtesy of KIA MOTORS AMERICA, INC.
15. Connect the RH oxygen sensor connector (A) and tighten the power steering hose mounting bolts (B).
  
  Fig 47: Identifying RH Oxygen Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting bracket (A).
Tightening torque:

88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)

Fig 48: Identifying Engine Mounting Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the coolant reservoir tank.
Remove the jack from the upper oil pan.
Install lower 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 TB1217H should be applied on oil pan.
  Bead width: 2.5mm (0.1in.).
  
  But marked area(*) to be 5.0mm (0.2in.)
  
  Fig 49: Identifying Liquid Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  1. Make clean the sealing face before assembling two parts.
  2. Remove harmful foreign matters on the sealing face before applying sealant.
  3. When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
  4. To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
3. Install the lower oil pan (A).
  Tightening torque:
  
  9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
  
  Fig 50: Identifying Lower Oil Pan
  Courtesy of KIA MOTORS AMERICA, INC.
Install the side cover.
Tightening torque:

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~7.9lb-ft)
Install the under cover (A).
Tightening torque:

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~7.9lb-ft)

Fig 51: Identifying Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH front wheel.
Tightening torque:

88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Install the intake air hose and air cleaner assembly.
1. Install the intake air hose and air cleaner assembly (C).
2. Connect the breather hose (B) to the air intake hose.
3. Connect the MAF sensor connector (A).
  
  Fig 52: Identifying MAF Sensor Connector
  Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover (A).

Fig 53: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Connect the battery negative cable (A).

Fig 54: Connecting Battery Negative Cable
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Refill engine with engine oil.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
  - Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
  - Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
  - Put radiator cap on tightly, then run the engine again and check for leaks.