Repair Procedures: Installation

Install the balance shaft chain. Refer to INSTALLATION .
Install the crankshaft chain sprocket (B) and the timing chain oil jet (A).
Tightening torque:

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

Fig 1: Timing Chain Oil Jet & Crankshaft Chain Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Set the crankshaft so that the key (A) of crankshaft will be aligned with the mating surface of main bearing cap. Put the intake and exhaust camshaft assembly so that the TDC marks (B) of the intake and exhaust CVVT sprockets will be aligned with the top surface of cylinder head. As a result of this, the piston of No. 1 cylinder is placed at the top dead center on compression stroke.

Fig 2: Identifying Crankshaft Key
Courtesy of KIA MOTORS AMERICA, INC.

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

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

Fig 4: Timing Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain. To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D).

Fig 5: Identifying Crankshaft Sprocket, Timing Chain Guide, Intake CVVT Sprocket & Exhaust CVVT Sprocket
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.

Fig 6: Identifying Timing Chain Color Links (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Identifying Timing Chain Color Links (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain tensioner arm (A).
Tightening torque:

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

Fig 8: Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the timing chain auto tensioner (B) and remove the stopper pin (A).
Tightening torque:

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

Fig 9: Timing Chain Auto Tensioner & Stopper Pin
Courtesy of KIA MOTORS AMERICA, INC.
After rotating crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm that the TDC marks (A) on the intake and exhaust CVVT sprockets aligned with the top surface of cylinder head.

Fig 10: Identifying TDC Marks
Courtesy of KIA MOTORS AMERICA, INC.
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 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, liquid sealant Loctite 5900H or equivalent 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: 3.0 mm (0.12 in.)
  
  Fig 11: Gap Between Cylinder Head & Cylinder Block
  Courtesy of KIA MOTORS AMERICA, INC.
4. After applying liquid sealant Loctite 5900H or equivalent on the timing chain cover.
  The part must be assembled within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path of oil leakage.
  
  Bead width: 3.0 mm (0.12 in.)
  
  Fig 12: Identifying Timing Chain Cover 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:
  
  Bolts A (M6x25) :
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Bolts B (M8x28) :
  
  18.6 ~ 22.5 N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6 lb-ft)
  
  Fig 13: Identifying Timing Cover Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: The engine starting or pressure tests should not be performed within 30 minutes after the timing chain cover was assembled.
Install the engine support bracket (A).
Tightening torque:

M10 bolts :

39.2 ~ 44.1 N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 32.5 lb-ft)

M8 bolts :

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

Fig 14: Engine Support Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft front oil seal (A) using SST (09214-3K000, 09231-H1100) (B).

Fig 15: Installing Crankshaft Front Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt tensioner (A).
Tightening torque:

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

Fig 16: Drive Belt Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the idler (A), the water pump pulley (B), the crankshaft pulley (C) and the drive belt tensioner pulley (D).
Tightening torque:

Idler (A) :

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

Water pump pulley (B) :

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

Crankshaft pulley (C) :

166.6 ~ 176.4 N.m (17.0 ~ 18.0kgf.m, 122.9 ~ 130.1 lb-ft)

Drive belt tensioner pulley (D) :

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

Fig 17: Idler, Water Pump Pulley, Crankshaft Pulley & Drive Belt Tensioner Pulley
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Tensioner pulley bolt is left-handed screw.

NOTE: Use the SST (Ring gear stopper, 09231-3K000) to remove the crankshaft pulley bolt. Install the starter after installing the crankshaft pulley.
Install the engine mounting support bracket (B) and connect the ground line (A).
Tightening torque:

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

Fig 18: Engine Mounting Support Bracket & Ground Line
Courtesy of KIA MOTORS AMERICA, INC.
Remove the jack from the ladder frame.
Install the oil pan.
1. Using a gasket scraper, remove all the old sealant material from the gasket surfaces.
2. Before assembling the oil pan, liquid sealant Loctite 5900H, Threebond 1217H or equivalent should be applied on oil pan. The part must be assembled within 5 minutes after sealant was applied.
  Bead width : 2.5 mm (0.010 in.)
  
  Fig 19: Oil Pan
  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 the oil pan (A). Uniformly tighten the bolts in several passes.
  Tightening torque
  
  Bolts B (M9) :
  
  30.4 ~ 34.3 N.m (3.1 ~ 3.5kgf.m, 22.4 ~ 25.3 lb-ft)
  
  Bolts C (M6) :
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 20: Identifying Oil Pan Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: After assembly, wait at least 30 minutes before filling the engine with oil.
  
  NOTE: Always use a new drain plug gasket.
Install the A/C compressor bracket (A).
Tightening torque:

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

Fig 21: A/C Compressor Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Install the A/C compressor lower bolts (A).
Tightening torque:

20.0 ~ 33.0 N.m (2.04 ~ 3.36kgf.m, 14.8 ~ 24.3 lb-ft)

Fig 22: A/C Compressor Lower Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt (A).
Crankshaft pulley → A/C pulley → Alternator pulley → Idler #1 pulley → Idler #2 pulley → Water pump pulley → Tensioner pulley.

Rotate the drive belt tensioner arm (B) counterclockwise moving the tensioner pulley bolt with wrench. After putting the belt on the tensioner pulley, release the tensioner pulley slowly.

Fig 23: Engine Drive Belt Routing Diagram
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 : 2.5 mm (0.10 in.)
  
  Fig 24: Area Between Timing Chain Cover & Cylinder Head
  Courtesy of KIA MOTORS AMERICA, INC.
3. Install the cylinder head cover (A) by tightening the bolts as following method.
  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 25: Cylinder Head Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 26: Cylinder Head Cover Tightening Sequence
  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 is assembled.
Install the front engine hanger (B) and then connect the PCV (Positive crankcase ventilation) hose (A).
Tightening torque:

27.5 ~ 31.4 N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1 lb-ft)

Fig 27: PCV Hose & Front Engine Hanger
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure fuel pump (A) and the roller tappet (B). Refer to INSTALLATION .
Tightening torque:

12.7 ~ 14.7 N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8 lb-ft)

Fig 28: High Pressure Fuel Pump & Roller Tappet
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

NOTE: Do not use already used bolt again.

NOTE: When tightening the installation bolts of the high pressure fuel pump, tighten in turn the bolts in small step (0.5 turns) after tightening them with hand-screwed torque.

CAUTION: Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

NOTE: Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.

Fig 29: O-Ring, Roller Tappet, & Protrusion
Courtesy of KIA MOTORS AMERICA, INC.
Install the high pressure pipe (A). Refer to INSTALLATION .
Tightening torque:

Bolt : 7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)

Nuts : 26.5 ~ 32.4 N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9 lb-ft)

Fig 30: High Pressure Pipe
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not reuse the high pressure pipe.
Connect PCSV (Purge control solenoid valve) connector (A) and tighten the vacuum pipe assembly mounting bolts and nut.

Fig 31: Purge Control Solenoid Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).

Fig 32: Fuel Hose & Purge Control Solenoid Valve Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the ignition coils (A).
Tightening torque:

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

Fig 33: Ignition Coils
Courtesy of KIA MOTORS AMERICA, INC.
Connect the ignition coil connectors (A) and fuel pump connector (B) after installing the wiring protector.

Fig 34: Ignition Coil & Fuel Pump Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Connect the exhaust OCV (Oil control valve) connector (A) and the oxygen sensor connector (B).

Fig 35: Oil Control Valve & Oxygen Sensor Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Install the under covers (A, B).
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 36: Under Covers
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the cover (B), install the cover with the mounting bracket.
Install the intercooler inlet pipe & hose assembly (C) and then connect the recirculation valve connector (A) and the vacuum hose (B).
Tightening torque

Pipe mounting bolt:

14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

Fig 37: Inlet Pipe Hose Assembly, Vacuum Hose & Recirculation Valve Connector
Courtesy of KIA MOTORS AMERICA, INC.
Install the intercooler inlet hose (A).
Tightening torque:

4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

Fig 38: Intercooler Inlet Hose
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH front wheel.
Install the air cleaner assembly.
1. Install the air cleaner assembly (E) and then connect the air intake hose (D).
  Tightening torque
  
  Hose clamp bolt :
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts :
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)
2. Connect the breather hose (A), the recirculation hose (B) and the brake booster vacuum hose (C).
  
  Fig 39: Breather Hose, Recirculation Hose & Brake Booster Vacuum Hose
  Courtesy of KIA MOTORS AMERICA, INC.
Install the air duct (B).
Connect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0 N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4 lb-ft)

Fig 40: Air Duct & Battery Negative Terminal
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine cover.
Add all the necessary fluids and check for leaks. Connect GDS. Check for codes, note, and clear. Recheck.
NOTE:
- Refill engine with engine oil.
- Refill transaxle with fluid.
- Refill radiator and a reservoir tank with engine coolant.
- 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.
- 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.