Repair Procedures: Installation

Align the timing marks of the camshaft sprocket with the upper surface of the cylinder head to make No. 1 cylinder be positioned at TDC.

Fig 1: Aligning Timing Marks
Courtesy of KIA MOTORS AMERICA, INC.
1. Check the dowel pin of the crankshaft for facing upside of the engine at this moment.
2. Install the timing chain guide (A).
  Tightening torque:
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 2: Identifying Timing Chain Guide
  Courtesy of KIA MOTORS AMERICA, INC.
3. When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.
  Order: Crankshaft sprocket → Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
Install the chain tensioner arm (A).
Tightening torque:

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

Fig 3: Identifying Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the hydraulic tensioner (A) and remove the pin (B).
Tightening torque:

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

Fig 4: Identifying Hydraulic Tensioner & Pin
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Recheck the top dead center (TDC) marks on the crankshaft and camshaft.
Install the timing chain cover (A).
1. Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
2. Apply the liquid gasket (TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.
  Width: 3 ~ 5 mm (0.1181~0.1969 in.)
  
  Fig 5: Applying Liquid Gasket Between Cylinder Head & Cylinder Block
  Courtesy of KIA MOTORS AMERICA, INC.
3. Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts of the timing chain cover and THREE BOND 1217H or LOCTITE 5900H on the rest parts. Reassemble the cover (A) within 5 minutes.
  Width: 3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in.)
  
  CAUTION: Thoroughly remove oil or dust on the surface.
4. Align the dowel pin of the cylinder block and the holes of the oil pump.
  Tightening torque:
  
  12 mm bolts:
  
  18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
  
  10 mm bolts:
  
  9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 6: Identifying Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: After the installation, do not crank engine or apply pressure on the cover for half an hour.
Using the SST (09455-21200), reassemble the timing chain cover oil seal (A).

Fig 7: Installing Timing Chain Cover Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft pulley (A).
Tightening torque:

127.5 ~ 137.3 N.m (13.0 ~ 14.0kgf.m, 94.0 ~ 101.3 lb-ft)

Fig 8: Identifying Crankshaft Pulley & Bolt
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 (09231-2B100) to hold the ring gear after removing the starter.
  
  Fig 9: Identifying SST (09231-2B100) 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 bracket (A).
  
  Fig 10: Identifying Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the dust cover (A) on the bottom of the ladder frame and unfasten the transaxle mounting bolt (B).
  
  Fig 11: Identifying Dust Cover
  Courtesy of KIA MOTORS AMERICA, INC.
3. Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
4. Adjust the angle of the links (D) so that the bolt 70 mm (2.7559 in.) can be fastened to the original mounted hole.
  
  Fig 12: Identifying Ring Gear, Holder, Links & Nuts
  Courtesy of KIA MOTORS AMERICA, INC.
5. Install the SST (09231-3D100) using the mounting bolts and spacers. Tighten the bolts and nuts of the holder and links securely.
  
  Fig 13: Identifying SST (09231-3D100) Holding Ring Gear
  Courtesy of KIA MOTORS AMERICA, INC.
NOTE: When installing the pulley, the groove on the pulley should be positioned outside.

Fig 14: Positioning Groove On Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install side cover.
Tightening torque:

8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)
Install the front right wheel and tire.
Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.
After applying the liquid gasket, THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.
Width: 2.0 ~ 2.5 mm (0.0787~0.0984 in.)

Fig 15: Identifying Liquid Gasket Application Area
Courtesy of KIA MOTORS AMERICA, INC.
Install the cylinder head cover (A) with a new gasket (B).

Fig 16: Identifying Cylinder Head Cover & Gasket
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Do not reuse the disassembled gasket.
Tighten the cylinder head cover bolts (A) with the order and steps.
Tightening torque:

1st step - 3.9 ~ 5.9 N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)

2nd step - 7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 17: Cylinder Head Cover Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Install the ignition coils (A).
Tightening torque:

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

Fig 18: Identifying Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Install the positive crankcase ventilation (PCV) hose (A) and the positive and PCSV hose (B).

Fig 19: Identifying Positive Crankcase Ventilation Hose & PCSV Hose
Courtesy of KIA MOTORS AMERICA, INC.
Connect the ignition coil connector (A) and the breather hose (B).

Fig 20: Identifying Ignition Coil Connector & Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt idler (A).
Tightening torque:

42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Fig 21: Identifying Drive Belt Idler
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump (A) with a gasket.
Tighten bolts with the order shown in Fig 22.

Tightening torque:

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

Fig 22: Water Pump Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A).
Tightening torque:

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

Fig 23: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tighten the bolts diagonally.
Install the engine support bracket (A).
Tightening torque:

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
Install the alternator bracket (B).
Tightening torque:

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

Fig 24: Identifying Engine Support Bracket & Alternator Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting bracket (A).
Tightening torque:

Nut (C):

78.5 ~ 98.1 N.m (8.0 ~ 10.0 kgf.m, 57.9 ~ 72.3 lb-ft)

Bolt (D) and Nuts (E):

58.8 ~ 73.5 N.m (6.0 ~ 7.5 kgf.m, 43.4 ~ 54.2 lb-ft)

Fig 25: Identifying Engine Mounting Bracket, Nuts, & Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Install the alternator (A) and pre-tighten the mounting bolts.

Fig 26: Identifying Alternator
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).

Fig 27: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Adjust tension by tightening the alternator tension adjust bolt (A). (Refer to DRIVE BELT TENSION MEASUREMENT AND ADJUSTMENT )
Tension

New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5 lb)

Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3 lb)

Fig 28: Identifying Alternator Tension Adjustment Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Tighten the alternator mounting bolts.
Tightening torque:

12 mm bolt:

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

14 mm bolt:

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)