Timing Chain: Installation

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 Of Timing Chain Cover
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) and LH timing chain (B).
Tightening torque:

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

Fig 4: Identifying Timing Chain Guide And Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket → Timing chain guide → Exhaust camshaft sprocket → Intake camshaft sprocket.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 5: Identifying Timing Mark (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 6: Identifying Timing Mark (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).
Tightening torque
1. 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
2. 18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)
Fig 7: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft sprocket (A) (O/P & RH camshaft drive).

Fig 8: Identifying Crankshaft Sprocket
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain sprocket (A) and oil pump chain (B).
Tightening torque:

18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)

Fig 9: Identifying Oil Pump Chain Sprocket And Oil Pump Chain
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain guide (A) and RH timing chain (B).
Tightening torque:
1. 19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft)
Fig 10: Identifying Timing Chain Guide And Timing Chain
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket →Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

Fig 11: Identifying Timing Mark (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 12: Identifying Timing Mark (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).
Tightening torque
1. 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
2. 18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)
Fig 13: Identifying Timing Chain Auto Tensioner And Timing Chain Tensioner Arm
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain guide (A).
Tightening torque:

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

Fig 14: Identifying Oil Pump Chain Guide
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain tensioner assembly (A).
Tightening torque:

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

Fig 15: Identifying Oil Pump Chain Tensioner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Pull out the pins of hydraulic tensioner (LH & RH).

Fig 16: Identifying Hydraulic Tensioner Pin (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 17: Identifying Hydraulic Tensioner Pin (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the oil pump chain cover (A).
Tightening torque:

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

Fig 18: Identifying Oil Pump Chain Cover
Courtesy of KIA MOTORS AMERICA, INC.
After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE: Always turn the crankshaft clockwise.
Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging from the sprocket teeth.
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 TB 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 : 2.5 mm (0.1 in.)
  
  Fig 19: Identifying Liquid Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
3. After applying liquid sealant TB1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied.
  Sealant should be applied without discontinuity.
  
  Fig 20: Applying Liquid Sealant On Timing Chain Cover
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - Fill the T-joint area (6EA *) with sealant.
  - Apply sealant all around the dowel pin hole (2EA).
4. Install the new gasket (A) to the timing chain cover.
  
  Fig 21: 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) :18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)
  
  C (4) :9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  D (2) :58.8 ~ 68.8 N.m (6.0 ~ 7.0 kgf.m, 43.4 ~ 50.6 lb-ft)
  
  F (2) :24.5 ~ 26.5 N.m (2.5 ~ 2.7 kgf.m, 18.1 ~ 19.5 lb-ft)
  
  G (4) :21.6 ~ 23.5 N.m (2.2 ~ 2.4 kgf.m, 15.9 ~ 17.4 lb-ft)
  
  H (1) :9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  I (1) :9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  J (1) :9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  K (4) :9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  L (1):21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5 lb-ft) - New bolt
  
  Fig 22: Identifying Timing Chain Cover Bolt Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
6. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Using SST (09231-3C100), install timing chain cover oil seal.

Fig 23: Installing Timing Chain Cover Oil Seal
Courtesy of KIA MOTORS AMERICA, INC.
Install the engine mounting bracket (B) and then connect the ground cable (A).
Tightening torque:

Bolts (C) & Nut (D) :

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

Fig 24: Identifying Ground Cable
Courtesy of KIA MOTORS AMERICA, INC.
Install the lower oil pan (A).
1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. Before assembling the oil pan, the liquid sealant TB 1217H should be applied on oil pan. The part must be assembled within 5 minutes after the sealant was applied.
  Bead width : 2.5 mm (0.1 in.)
  
  Fig 25: Identifying Liquid Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
  CAUTION:
  - Clean the sealing face before assembling two parts.
  - Remove harmful foreign matters on the sealing face before applying sealant.
  - When applying sealant gasket, sealant must not protrude into the inside of oil pan.
  - To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
3. Install the oil pan (A).
Uniformly tighten the bolts in several passes.

Tightening torque:

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

Fig 26: Identifying Oil Pan
Courtesy of KIA MOTORS AMERICA, INC.
Install the crankshaft pulley (A).
Tightening torque:

284.4 ~304.0 N.m (29.0~31.0 kgf.m, 209.8~224.2 lb-ft)

Fig 27: Identifying Crankshaft Pulley
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 28: Installing SST (09231-2B100) To Hold 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 front muffler. (Refer to INTAKE AND EXHAUST SYSTEM )
2. Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
  
  Fig 29: 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. Fasten the two transaxle mounting bolts in the original mounted holes.
  
  Fig 30: Adjusting Length Of Holder Nut
  Courtesy of KIA MOTORS AMERICA, INC.
5. Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
Fig 31: Installing SST (09231-3D100)
Courtesy of KIA MOTORS AMERICA, INC.
Install the water pump pulley (A).
Tightening torque:

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

Fig 32: Identifying Water Pump Pulley
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt auto tensioner (A).
Tightening torque

Bolt (B) :81.4 ~ 85.3 N.m (8.3 ~ 8.7 kgf.m, 60.0 ~ 62.9 lb-ft)

Bolt (C) :17.7 ~ 21.6 N.m (1.8 ~ 2.2 kgf.m, 13.0 ~ 15.9 lb-ft)

Fig 33: Identifying Drive Belt Auto Tensioner
Courtesy of KIA MOTORS AMERICA, INC.
Install the drive belt idler (A).
Tightening torque:

53.9 ~ 55.9 N.m (5.5 ~ 5.7 kgf.m, 39.8 ~ 41.2 lb-ft)

Fig 34: Identifying Drive Belt Idler
Courtesy of KIA MOTORS AMERICA, INC.
Install the alternator (A). (Refer to ALTERNATOR .
Tightening torque:

26.5 ~ 33.3 N.m (2.7 ~ 3.4 kgf.m, 19.5 ~ 24.6 lb-ft)

Fig 35: Identifying Alternator
Courtesy of KIA MOTORS AMERICA, INC.
Install the air conditioner compressor (A). (Refer to COMPRESSOR .

Fig 36: Identifying Air Conditioner Compressor
Courtesy of KIA MOTORS AMERICA, INC.
Install the power steering pump (A). (Refer to POWER STEERING OIL PUMP .

Fig 37: Identifying Power Steering Pump
Courtesy of KIA MOTORS AMERICA, INC.
Rotate the auto tensioner counter - clockwise. With the tensioner turned, install the drive belt on auto tensioner and then release the tensioner.

Fig 38: Engine Drive Belt Routing Diagram
Courtesy of KIA MOTORS AMERICA, INC.
Install the LH/RH cylinder head cover (A).
CAUTION:
- Install the cylinder head cover under the exhaust OCV cap is removed.
- To prevent engine oil leakage, surely install the exhaust OCV cap after installing 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 : 2.5 mm (0.1 in.)
  
  Fig 39: Identifying Sealant Apply Area
  Courtesy of KIA MOTORS AMERICA, INC.
3. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
4. Install the cylinder head cover bolts as following sequence.
  Tightening torque:
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
  Fig 40: Identifying Cylinder Head Cover Bolt Tightening Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
  
  CAUTION: Do not reuse cylinder head cover gasket.
5. Install the exhaust OCV cap (A).
Tightening torque:

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

Fig 41: Identifying OCV Cap
Courtesy of KIA MOTORS AMERICA, INC.
Install the surge tank. (Refer to INTAKE AND EXHAUST SYSTEM .)
Install the other parts with reverse order of removal.

NOTE:

Refill engine oil.
Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
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 lines.
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 and let it cool down. 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.